To take it apart and clean it and reinstall it is for the beginner pretty much an all day thing because you will want to remove the manifold as well and clean that too. I can show you how to clean that with a solvent tank or a torch or compressed air - they all work.

Now, driving it like you stole it is very important. Kind of like not idling a CTD - bad news - well in this case shifting too low and you are going to carbon up, loose power, mileage and make all sorts of codes go off and depending on the year, go into limp mode - I've done that a few times - it isn't fun. Of course 2 times were because of a boost leak and one time was from dead glow plug harness but hey, they fix easy.

Good stuff - thx.

Anytime.

Wonder if anyone can help. I have a 2nd hand 2000 year Bora (that's the European name) with the 115BHP PD engine and around 50K miles. It's been absolutely fantastic save for a flat spot between 2200-2600 rpm in higher gears. 3,4,5,6. Last time it was in for service I asked the garage to check it out as the warranty will soon run out and I thought maybe the turbo might be on the way out.

They scratched their heads for a few days then told me it needed a new intercooler - which they duely fitted. Now, sure enough, the flat spot has gone - but the torque below 2000rpm in all gears is now WAY down. Is it possible that the broken intercooler was resulting in an overboost low down ( no idea if that's technically possible - I'm not technical) - and now that they've fixed the problem the performance is what it should be? Or are they just yanking my chain and it's likely the problem lies elsewhere and they've just replaced the easiest component in the chain??

Like I say - I'm not technical - so any tekkie input would be much appreciated!!!

Many thanks!

First welcome.

Next, The Bora for those that don't know is the EU Jetta. I have an estate which is a Jetta Wagon here. Anyway, a 2000 PD motor is something we don't see here at all so my guess is this:

The PD motor is known to have a turbo squawk and a bearing squeal under specific conditions. Intercoolers are poorly positioned on all VW's and can easily get damaged and or plugged if not taken care of. That's another matter unto itself. The low power and flat spot is a fueling problem and is either fixed with a computer flash which VW (Canada) has for sure or with the use of a Diesel Tuning Fueling Box. Also, we don't have 6 speed manuals over here on VW diesel product so I can't comment on that Audi drive train as I have never had to do anything with it.

All I can offer there is drive it like you stole it and get it hot - see if you've got a plugged EGR or exhaust manifold which is very likely and get those cleaned and functioning again. All easy to do mind you - just takes time and some good tools. The first time I did it from start to finish it was 10 hours and I can now do it in 4 hours so...

It won't be anything to do with your boost level (persay).

Hopefully that helps.

Lastly, where do you live?

Cheers,

jetta
 

i drive a CTD 06 dodge and my wife drives an 02 TDI. looking to hook her up with an upgrade or two that might get her more power, better mpg. any suggestions for programmers and intakes that might help in this area? when she's done with the thing (wheels fall off) i'm gonna put the engine in a suzuki samurai. heard there was a trick kit for a quick install. anyone know an outlet for such a beast??

Look here Jeff - Suzuki Samurai Turbo Diesel

Yes and no.

The 2002 TDI can't get better mileage if it is running as it should be when properly maintained. This mileage is around 50 imperial miles per gallon (a little less in USMPG).

Anyway, it sounds to me of a few things:
1. how do you or her drive this car? You need to drive it like you stole it - it must shift high, avoid idles and run a little hot to be any use. No I don't mean the rad must be screwd with or anything - it's just these cars must be warm before they act like they should. Don't idle to get there though - it will never warm up.
2. Is is an auto? If so it is likely carboned up and must be cleaned or de-carbed. To do this you will either take it to a dealer and they will charge you around $1000 or you get a good set of tools, a parts bin cleaner tub and a 1L jug of spic and span and go nuts.
3. Tire pressure, air filters, fuel filters and glow plugs will all result is lower mileage if they are not as they should be.
4. There is a well documented dead spot on the throttle curve in these cars from about 2900 to 3300 when in 3rd or 4th gear. A diesel tuning box (that's what it is called) which is basically a fueling box will fix that. So would injectors, a better exhaust and a turbo but most people with VW products are cheap so I wouldn't expect that to happen.

Now the transplant - there is no trick kit available to do this swap. It does however almost bolt right up and with a couple custom engine mounts you can go nuts. I've never done that but know of some who have.:c:

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Never seen that info before. Cool.

Im sure there are probably other kits on the market as well.

I have an 06 Jetta TDI and love it. I have all my maintenance done at a local dealer in CO run by a German with a bad sence of humor (I was stationed there for 4 yrs and loved it). Avg mileage is 40ish around town if I let the wife drive it too much and best tank was 700 miles/53mpg hwy. I'd like to get more power or better MPG out of it. The drive it like you stole it mantra seems contradictory to common sense, but if you say so.
Does this apply to 05.5 + TDIs as well?
Wouldn't the higher shift point use more fuel?
I'm assuming this is shift point only and not necessarily implying a heavier foot?
Thanks for posting this on here. It's nice to find info for 2 of my vehicles in one forum.