New TDI Jetta Project/DD

[wolfsburged]

Haven't posted over in the TDI section before, but now I have many reasons to lurk here as well as the IDI forum!

Picked up this 2001 TDI Jetta GL with 114k for a song. Has an auto that is stuck in park. Will be fixing up and swapping to a manual trans for daily driver status. Very clean exterior, paint is in great condition. Needs a windshield. Interior is a little dirty, hoping to find a nice leather interior to swap.

GL model so crank windows and no sunroof. Nothing to break there.

Engine cranks over great and sounds perfect reving in neutral.

The automatic seems like it is stuck in park/neutral. You can put it in any gear, D, R, 3, 2, 1 and rev, and nothing at all, no attempts to move. Indicator on the cluster moves and indicates correct gear selection.

I can roll it forward in Neutral, but cannot roll it backwards. I would love to at least make this thing be able to roll backwards, not sure why it won't.

Looks like someone was messing with a bit of wiring under the hood. A few electrical related codes showing up. Will have to go through the wiring and fix some of that, who knows maybe the auto will start shifting?!

Pics:






Elusive "TDI, Ja!" edition





















Suspect wiring



Suspect wiring

Codes:
19586
http://wiki.ross-tech.com/wiki/index...6/P3130/012592
19586/P3130/012592 - EGR System: Regulation Range Exceeded
Possible Symptoms

    Malfunction Indicator Light (MIL) ON

Possible Causes

    Exhaust Gas Recirculation (EGR) Valve (N18) faulty
    Exhaust Gas Recirculation (EGR) faulty

Possible Solutions

    Check/Replace Exhaust Gas Recirculation (EGR) Valve (N18)
    Check Exhaust Gas Recirculation (EGR) faulty


00652
http://wiki.ross-tech.com/wiki/index.php/00652
00652 - Gear Monitoring: Implausible Signal
Possible Causes

    Automatic Transmission Fluid (ATF) Level not OK
    Vehicle Speed Sensor (G68) dirty/faulty
        Impulse Wheel dirty or Installation faulty
    Gearbox Speed Sensor (G38) dirty/faulty
        Impulse Wheel dirty or Installation faulty
    Multi-Function Switch (F125) faulty (but not detected)
    Clutch or Valve Body faulty
    Automatic Transmission Fluid (ATF) Pump faulty

Possible Solutions

    Check Automatic Transmission Fluid (ATF) Level
    Check/Clean/Replace Vehicle Speed Sensor (G68)
    Check/Clean/Replace Gearbox Speed Sensor (G38)
    Check/Replace Multi-Function Switch (F125)
    Check/Replace Clutch and/or Valve Body

Special Notes

    The ratio of engine speed to gearbox output speed in the currently engaged gear is implausible.
    Slip rpm with torque converter lock-up clutch disengaged must be greater than stall speed.


00300
http://wiki.ross-tech.com/wiki/index.php/00300
00300 - Transmission Fluid Temp. Sensor (G93) - Implausible Signal
Possible Symptoms

    MIL On
    Transmission Not Shifting Properly or in Limp Mode

Possible Causes

    Wiring/Connectors from/to Transmission Fluid Temp. Sensor (G93) faulty
    Voltage Supply for Transmission Fluid Temp. Sensor (G93) faulty
    Transmission Fluid Temp. Sensor (G93) faulty

Possible Solutions

    Check Wiring/Connectors from/to Transmission Fluid Temp. Sensor (G93)
    Check Voltage Supply for Transmission Fluid Temp. Sensor (G93)
    Check Measuring Blocks for Transmission Fluid Temp. Sensor (G93) Readings
    Check / Replace Transmission Fluid Temp. Sensor (G93)


01192
http://wiki.ross-tech.com/wiki/index.php/01192
01192 - Torque Converter Lock-Up Clutch
01192 - Torque Converter Lock-Up Clutch: Mechanical Malfunction

Possible Symptoms

    Torque Converter Lock-Up Clutch slipping

Possible Causes

    Torque Converter Lock-Up Clutch faulty
    Valve Body faulty
    Internal Failure in Transmission

Possible Solutions

    Check Torque Converter Lock-Up Clutch Slip

Special Notes

    When found in 4-Speed Automatic Transmission (01M), check Measuring Value Block (MVB) 007.


00668
http://wiki.ross-tech.com/wiki/index.php/00668
00668 - Supply Voltage Terminal 30: Signal Outside Specifications
00668 - Supply Voltage Terminal 30: Implausible Signal

Possible Causes

    Fuse(s) faulty
    Wiring/Connectors from/to Control Module faulty
    Power Supply (Battery/Generator) faulty

Possible Solutions

    Check Fuse(s)
    Check/Repair Wiring/Connectors from/to Control Module
    Check Power Supply (Battery/Generator)

Special Notes

    When found in an individual control module, it's most likely a local source (e.g. wiring/connectors).
    When found in multiple control modules at the same time, it's most likely a common source (e.g. ground spot, battery, generator).
    Intermittent codes are often stored during low outside temperature when the battery capacity goes down and may be ignored.







00532
http://wiki.ross-tech.com/wiki/index.php/00532
00532 - Supply Voltage B+: Signal too Low
Possible Causes

    Wiring/Connectors from/to Control Module faulty
    Power Supply (Battery/Generator) faulty

Possible Solutions

    Check/Repair Wiring/Connectors from/to Control Module
    Check Power Supply (Battery/Generator)

Special Notes

    When found in an individual control module, it's most likely a local source (e.g. wiring/connectors).
    When found in multiple control modules at the same time, it's most likely a common source (e.g. ground spot, battery, generator).
    Intermittent codes are often stored during low outside temperature when the battery capacity goes down and may be ignored.
    Common with 16946/P0562/001378 - System Voltage: Too Low stored in other control modules.


01316
http://wiki.ross-tech.com/wiki/index.php/01316
01316 - ABS Control Module: No Signal/Communication
Possible Causes

    Wiring/Connector(s) from/to ABS Control Module faulty
    Fault(s) stored in ABS Control Module

Possible Solutions

    Check Wiring/Connector(s) from/to ABS Control Module
    Check Measuring Value Blocks (MVB)
        Usually Measuring Value Blocks (MVB) 125+ show the current Communication Status

01389
No Ross-Tech Wiki info.
VAG-COM info: Tailgate open switch (F124), Short to Ground intermittent.

[theman53]

since you are swapping a manual, let me know if you figure out how to get reverse lights. I have been through it, somehting on mine just isn't working.

[BigVWman]

Reverse lights aren't that hard, toughest part of swap I had was finding all the parts!
Nice find! You can really score a goo deal when they have the auto, lots of folks unwilling to put in the wrench time to do the swap!

[JessaBug]

Yeah luckily there is a donor locally for the swap. Had that figured out before we jumped on getting the car. Glad we got it though. Very straight. Great starting point for sure. It would be nice to get the auto fixed if possible without too much effort just so we can take our time with the swap. We have VAG-COM and a lot of the codes seem to be related to some electrical issue...bad wiring, bad ground, battery connections not tight enough...something. We'll be tinkering slowly. But it should be fun and a great car once we're done with it. Nice addition to our '84 TD and my GTI!

[BigVWman]

IF it has the proper level of fluid and still won't move at all even in manual selection my guess would be a hard parts failure inside the trans itself, maybe the slipping got so bad the PO exploded the planetary gear set or melted down the forward clutch pack. Should search some of "coolair" s posts on tdiclub or vortex, he is kinda the 01m guru. I have rebuilt a couple and they are nice but IMO overly complicated and temperamental for what they really need to do. On the swap there are alot of guides(instructables, kill da wabbit, etc). Beware the wiring colors don't match in most of them! Is the donor also a tdi? The gear ratios are better on the tdi versions! lkq is great for the little stuff you forget you need, they were my saving grace!

[JessaBug]

Donor is another Jetta TDI so that's no problem on the gearing. We've spent a lot of time over at LKQ. Haven't been in awhile (mostly because going there means we spend money and we've needed to save  ). I'm sure we'll get up there soon but first things first is to see if we can get this thing running again!

[wolfsburged]

Went over tonight and secured the donor car. It is a 99.5 TDI Jetta. Will be spending some time reading up on the swap and getting my parts list together. It is at a local friendly shop so I am parting it out there and taking the stuff back home in probably 2 weekends.

[Baron VonZeppelin]

Heavy Duty Congrats on the TDI to you two. :thumbsup:

So how much is a song selling for these days ?
1k 2k 3k Free K ?

A set of 4 wheel dollies would be handy until the tranny comes out.
Spin it around in the shop like a bottle.
Or drag it in and out with a riding lawnmower with dollies under front wheels.

Tranny sounds like its beyond a quick fix.
Maybe disconnect axles from trans flanges ?

[wolfsburged]

Already got a set of dollies on the front.

Picked this thing up for $2000 cash. Just secured a 5 speed TDI shell minus engine but all other pieces complete for $700. Now the research begins!

[Baron VonZeppelin]

FukknGroovy Bill !!

Ya'll have this project by the balls and the bases are loaded.
Knock it outta da pahhrk.

Very gelly about being all in on a nice TDI with 114k and 5spd upgrade
for probably under 3K done ! Dang thats heavy

[JessaBug]

Will be doing a timing belt job too, so probably a bit over 3, but we should be into the car for probably half of what we'd buy it for as a 5-speed already, which we're pretty excited about 

Gonna be slow-going. In-laws in town this weekend...really almost every weekend is spoken for in Feb already so it will be nights after work researching and slowly tinkering. Hopefully come March we'll have more time to get working on this thing more.

[Baron VonZeppelin]

Heck yeh Jess, probably closer to TRIPLE that much around our area for a clean TDI with that low of mileage and a 5spd.
No telling what a dealer would ask.

You guys have really scored big this time.
Real happy for you too.

Looks like all 3 of us will be having to add new chapters in our diesel knowledge now...
Surprisingly, they reconsidered and decided to accept Ingold's "take it or leave it" offer for the 98 TDI 5spd with 116k.

He gets it tomorrow, and he's Real Happy about it.
I wrench all his Diesels, and i'll be the wrench on this one too.

The CarFax has last owners name, going to (hopefully) contact them and (hopefully) find out whether or not they did the belt anytime prior to trading it in.

[theman53]

To you and your new ride...

[JessaBug]

Luckily, these ALH's aren't that much more complicated than the 1.6's. Already starting to research but we know a few people with them too so we should be good on that. And I know a decent amount of Mk4 stuff so Bill's been asking me a bunch of questions (pretty fun to be the one who knows more for once  ).

[wolfsburged]

Collecting swap parts and researching...

Decided for kicks to drain the fluid and inspect the pan on the auto.

Here's some nice metallic sludge on the pan magnet:


Filter was disintegrated:


And of course ATF is not supposed to look like this!


Bought this car as the 5 speed swap donor:


215K, front end accident. Bought car minus engine for swap. Interior moldy, didn't save much else except the swap bits I needed. But I did end up with a nice selection of spares, including a VNT15 turbo w/ manifold, alternator, instrument cluster (may swap to remove extra PRNDL screen), all pedals (for the small brake pedal), brake booster & master cylinder, center stack w/ HVAC controls, power steering pump, and some misc. other stuff.





Took the power washer and some Purple Power to the engine bay, came out awesome:


Scored this for free! Going to reglue a few small spots starting to come undone and replace the totally sagging headliner in the car:


I think based on needing to do a timing belt on top of the swap, I will pull the core support and use an engine hoist to remove everything, then do the transmission mating out of the car for ease, and then have access to the timing belt side with ease. Also can do more cleanup. I'm planning on pulling the EGR and intake to clean really well. This way I can get in for wiring and also will probably go all the way to swap the manual brake pedal cluster in as well.

Put together my first round of parts order. Clutch/flywheel, lots of one time use bolts, maintenance bits.

More to come (but not rushing!)...