My Jetta GLI

Started by 80 Vert, November 01, 2023, 10:21:30 PM

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80 Vert

With the engine bay looking pretty complete there's still a few parts I'm waiting for, the seat belts from Safety Restore were on their way back to me by this stage. They have been a pretty phenomenal company to deal with.
The coolant elbow turned into a bit of a faff, FCP Euro claimed 2 days before they could ship but nearly a week later they still hadn't shipped it so after a bit of to and fro with them I decided to just order one from the local VW dealer which was special order and had to be pre paid.
Once that was done I went back to FCP to cancel the other one only to be told it had arrived and been shipped out D'OH!!
Next day FCP order arrived with my elbow.......as it turned out the one I ordered from the dealer I ordered wrong in any case so all a bit of a balls up.
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2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

Seat belts in hand I fitted those, they replaced all 6 gas charges for the pre tensioners and re set the belts so it was merely a case of fitting them back into the car. I took my VCDS cable and a new laptop with me for this purpose so plugged that in and cleared the codes, light out. Win.
Did a full scan and clear only leaving a couple random codes for things like low refrigerant pressure etc.
Coolant elbow in hand I completed the cooling system and filled it with coolant. I didn't have a vacuum filler so back to old school way of doing things, fill it up and idle it till the thermostat opens. Sounds simple right?
Anyway, that wasn't so easy. Left it running for a while and got two fault codes for trapped air in the heater pump.
Even a VW pdf suggested a vacuum filler for these codes but there has to be another way, using VCDS I ran the output test for the heater pump and circulation pump many times to purge the air out which worked.
Left the engine running with VCDS hooked up waiting for the thermostat to open, which didn't. Hmmm.
Temps got up to 108 deg c, cooling fan came on but the radiator outlet stayed at 20 deg c which made me worry that electric stepper motor thermostat was cooked. These combined water pumps have a host of issues and I started thinking mine was fried.
A bunch of research later I found VCDS can open and close the thermostat as a basic setting, tried this the next morning and basic setting completed successfully backed up by audible noise from the pump. Ok so what is it. Ran it again and same result, bottom hose stays cold but this time with the engine at 108deg I shut it off and used basic setting to open the thermostat which immediately increased the radiator outlet to 55deg so
my theory was the car wasn't getting hot enough just sitting there idling. As a backup I ordered a new pump anyway from FCP just in case.
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Following morning with VCDS monitoring temps I took it for a drive, no insurance or registration I kept it very local but trans shifts nice and getting on it a bit temps soon rose and as predicted the thermostat opened and all was normal. Just over thinking it but considering it was crashed anything was possible, including a blown head gasket.
Car went well, boosts well and no fault codes. You do notice the lower HP a lot as these are only rated at 228hp but in time an IE stg 1 will go in bumping that up to 300hp.
2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

Registration time, being that it was an out of state car I needed a VIN verification done but insurance is a big deal here so one is reluctant to drive an unregistered car in Arkansas and I thought I couldn't get insurance on a salvage title. (I learned later I could have done that)
We ended up going down to the DMV to ask what was required and my paperwork for the repair aspect was all in order, I was told I needed a VIN verification and insurance for the title to be switched from Salvage to Rebuilt. Tags and a plate would be able to be processed the same day.
DMV and Police do VIN verifications but the car would ideally need to be towed as it wasn't insured, decided to call by the Police station on the way back and the officer there called the local Sheriff to ask if he would come by the house to do it, no problem! 45 mins later the Sheriff was at the door, took less than 5 mins and the job was done. Super nice guy too.
Off to the insurance office, lady there didn't think I could get insurance with a foreign driver license but I showed her the insurance I'd had on my Mustang back in 2016.
She made a call to head office and sure enough that wasn't a problem, 30 mins later insurance sorted and back to the DMV.
With my VIN verification, insurance and repair paperwork the registration was processed and I was given a plate and tags. Too easy.
When registering a vehicle in this state you pay 6.5% sales tax but since mine was under a certain value it was only 3.5% plus $25 for the registration.
IMG20240516120117 (1).jpg
2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

#23
Next job on the list was the A/C, as I've had to replace the condenser with a new one the system needed a re gas.
Again super easy in the land of the US and A, go down to your local Walmart, O'Reilly auto parts or Autozone and you can buy cans of R134A for around 10 bucks each.
R134A is not something you can even get easily in NZ and what is available is expensive.
They have large cans here as well with a gauge and trigger but these are more for topping up rather than a full system fill. Not to worry though O'Reilly and Autozone have FREE yes, free loan tools to do this at home so you pay what the tools cost retail and when you return them you get a full refund.
In my case it was just over 400 usd for a set of A/C gauges and a vacuum pump, took these back to my brother in laws and pulled a vacuum on the system and then with the cans I'd bought from Walmart gassed it up. It took one full can and we weighed the 2nd one to ensure the correct amount went in and also putting in some compressor oil due to what was lost with the condenser swap.
Nice cold A/C for 25 bucks! Just so so easy.
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Next morning I could actually drive my newly repaired and registered car down to O'Reilly to return their tools and test the A/C properly, works flawlessly.
One tyre had a cut in it and I'd ordered another one the same off Ebay which had arrived several days earlier so I took that down to Walmart Auto Center for them to fit and balance it. Nearly time to hit the road for a 1200 mile road trip to help a friend.
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2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

superfueler

The front of the car looks clean with no plate on. Great job.
Current: 2007 Audi A4 2.0T DTM sprint blue, 2007 VW Golf V 2.0 TDI BKD 4motion manual white.
Past: Audi A4 2.7 TDI silver, 2004 Golf 4 R32 black pearlescent, 2009 Audi S3 8P white / panoramic roof, 2004 Audi A4 B6 1.8T blue, 99 Golf mk4 GTI black, 2005 Audi A4 B7 2.0T black.

80 Vert

#25
With all of that done we hit the road on our 3 day 1200 mile road trip East taking us through Arkansas, Tennessee, North Carolina into Virginia. Did 500 miles the first day which was a little much and had nothing but a low tyre pressure warning come up. Interestingly service stations here charge you for air! Yep couldn't believe it at first but then 2 bucks isn't exactly a lot either.
Car went well other than a very noisy growly tyre in the back, has a horrible vibration too at 70mph right where you mostly sit at.
Next stop took a look at that and its some cheap nasty rock hard 480 treadwear chinese garbage tyre. The other side rear is a Firestone which is quiet so I'll end up getting another one of those to match giving me two pairs on the car.
Keeping an eye on coolant and oil until I know what it's habits are but all seems fine so far.
Before we left I was messing around with VCDS and enabled auto roll down / up of all the windows from the keyfob.
There were a couple of existing codes in the right doors, one of which was no communication to the right rear door and the passenger sill entry light doesn't work either. The door codes stopped the window roll down working but once you clear the codes it does work a couple of times till the codes pop up again.
In the next couple of days I'll spend an evening at the motel messing with that, checking door wire harness first and going from there. Those couple of codes are the only ones in the entire car so I'd like to resolve them.
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2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

#26
With our 1200 mile drive taking us to Newport News in the state of Virginia to help a friend with a not so nice situation he's found himself in, he was certainly glad to see some familiar faces and appreciated the help.
The Jetta once again coming into its own, carting around 3 people and all of their belongings with ease. Believe it or not but everything fits in the boot which is pretty amazing and I love it.
Many runs to Harbor Freight tools, Home Depot and Walmart to get things we need to solve one of his problems.
It's returning around 16-17km / L which is really amazing, uses zero oil or coolant and after around 2000+ miles now the oil is still perfectly clean.
Got another Firestone tyre shipped to me via Ebay and had that fitted locally, lucky I was there watching him as he was going to put the wheel back on without balancing it WTF?
Once I told him I wanted it balanced he charged me an extra $10 on top of the $30 fitting fee (USD) which I thought was a excessive.
The final straw was him using his impact to put the wheel back on, at that point I told him to go away and did it myself by hand.
Tyre fitted my horrible noise is gone so all seems well, need to get it on the highway and see how it is at 70-80mph.
It's funny how NZ has gone crazy with banning plastics and conserving energy etc, once you've been here a while you realize all of that is a total waste of time as everything here is wrapped / packaged in plastic, fuel is still cheap so lots of people still drive large pickups with V8's and supermarkets hand out plastic bags by the 100's.
The amount of plastic waste at our Hotel breakfast is crazy, it's just the way it is.
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2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Pristle

Quote from: 80 Vert on May 27, 2024, 12:32:44 PMCar went well other than a very noisy growly tyre in the back, has a horrible vibration too at 70mph right where you mostly sit at.
Next stop took a look at that and its some cheap nasty rock hard 480 treadwear chinese garbage tyre. The other side rear is a Firestone which is quiet so I'll end up getting another one of those to match giving me two pairs on the car.

I almost replaced a rear wheel bearing with the noise I was experiencing on the Mk5 Wagen not long after I bought her. The owner of the shop I took it to grinned and said "let's get it on the hoist'. He then showed me how 'blocky' the tyres were. "Two things: 1. the wheels are wrong, not right offset for the car and 2. cheap Asian tyres, get decent brand". Some may offended by the latter, but Edwin is Asian.