just got a 96 passat tdi

[TBurow]

how durable are theese things? 1. 9 tdi 5 speed. any mods for power and mileage besides cut the cat and muffler off and replace the air cleaner? already in the works:-laf

and dont tell me to go to the vw sites, most people here drive other diesels when not driving their cummins.

thanks for any help.

 

[broncojohn]

I'm not to sure but I thought I heard someone say before Piers diesel has something for the VW TDI's. I am not to sure but couldn't hurt to check. Good luck.

 

[TowPro]

Plenty of mods out there for that baby, you can get chips, but you have to have the ECM changed for a chip socket. There is a mod where you put a resister between 2 wire connectors for a seat of the pants boost in power.
with a computer program called VAG-com you can turn down the EGR. It should last as long as a Cummins. Just replace the timing belt and tensionsers often. I think that version is every 50K miles.

But you said don't send you to the VW sites. If you change your mind, look up Freds TDI page. Its free.

 

[TBurow]

great, thanks. anyone know if removing the cat will trigger the check engine light? it has two thermocouples in it and a valve to spray fuel into it i guess to burn off the soot.

 

[TowPro]

I think there was a TSB to have that valve removed. I think that valve ended up causing tons of smoke. (kind of like Fords new one that causes 4' flames out the exhaust!). This TSB also included a free ECM upgrade if I recall (actual replace the ECM if I). You should go to a VW dealer and have them run the VIN. THere might be some open stuff on it they will do for free. If I recall, there was also a recall (or something like a recall) to give you a free intake manafold. Those era engines had a problem with the EGR gas would be cooled, then enter the intake manafold where it could condense into crud. I cleaned my 98 TDI, the holes in the intake were about the 3/4" after the crud buildup. They are about 2" after cleaning!



All my TDI knowledge came from Freds TDi website.

 

[TBurow]

just cut the cat off and it was almost plugged solid. runs great now.

it looks like the inj. pump is a vp44 is that about the same as the dodge ones?

 

[biggieou]

I'm looking at a 96 Passat as well. It has 199k on it and the body seems to be in pretty good shape(havent looked at it personally, just through pics). How much is one of these worth? The guy is asking $5500 and I thought that was kinda much.

 

[BGlidewell]

I put my TDI on cars.com and a dealership is offering me high retail for it. They're hard to find.

 

[biggieou]

Is there anything specific that I should look for when looking at a TDI?

 

[TowPro]

Yes, documentation showing when the last time the timing belt was changed. If the belt breaks the valves hit pistons. Some times you can just replace the bent valves, other times it needs valve guides and cam shaft replaced.

Earler TDI's had belt change requirements of 60K, some 80K.

If your looking at a 96-2005, you might find the intake clogged shut. Its not a bad job, just a dirty job to clean it out. The Jury is still out on the 2005. 5 on intake clogging.

The intake will clog bad enough that your boost will "spike" as the turbo tries to push air through a small hole. This can trigger the ECM into limp mode during a WOT throttle run.

 

[AKaiser]

Fred's TDi page

Did you look at http://www.tdiclub.com? There's all kinds of TDi specific stuff, including performance enhancements. When you need your eyes checked, you don't go to the dentist.

 

[biggieou]

Yeah I checked it out, but I know there are enough diesel nuts on here to help me out as well.

 

[TBurow]

theese things are great im getting 55+ mpg at 70-75 mph and they pull pretty good for a small four cylinder. ride is great also.

 

[CogginsP]

I have heard of people chipping these things out and putting different injector nozzles on there... big HP gains



From what I have heard they are very very fun to soup up, and inexpensive. I would love to own one.

 

[BILLVO]

theese things are great im getting 55+ mpg at 70-75 mph and they pull pretty good for a small four cylinder. ride is great also.

55+mpg from a passat . I have an03 jetta tdi and average 43 overall at 70-75 mph. I know several people with golfs and beetles with the 1. 8 that don't even get that good unless they stay under 65.



I have read lots on tdiclub.com and 1 thing I have read many times is that the factory airfilter set up is as good as it gets. Many tests on aftermarket systems netted no gain in anything. As you already did open up the exhaust. the timing belt on the earky ones is a must every 80k miles and intake cleaning also a must at least at timing belt changes.



My only mods are a TDI heater and a panzer plate "Skid plate" This is a must if you drive where there are gravel roads or uneven roads. I tore my lower plastic engine cover off the first week I had it and had some skid marks on the oil pan from gravel road rocks/ridges . The #1 killer of the TDI is lack of clearance and no oil pan protection. Check into it before you do any other things.

 

[TBurow]

i drive 100 miles to and from work each day, all highway, set the cruise ans relax. was getting 45mpg when i got it with the plugged cat and stock(dirty) air filter. 2-1/4 straight pipe no cat 18 inch glasspack even sounds quiet. removed the fuel injection system for the cat. worst milage 48. 5 with alot of city driving, best 56. 5 all highway. just replaced rear struts and front mounts, new timing belt kit came in mail today from ebay $135. with all belts tensioner idler cam seal and valve cover gasket. from metalmanparts. t belt and intake cleaning are next weeks project.

 

[TowPro]

billv, what year VW do you have? I had a 98 Jetta that got tottled when someone rear ended me. I was sitting still, she hit me at 45mph. The impact did not hurt me at all as the trunk area just folded up (her bumper was higher then mine)

We now have a 2005. 5 Jetta with the new injection system that uses the cam instead of the injection pump. I used to get 42 all the time in the 98 running it hard. With the new Jetta, my wife gets 38, and I get 42. Love that DSG transmission, Its a manual trans that the computer shifts and works the clutch for you!

You mentioned Air filters, the 99-200? had problems with the Air Flow Sensor, then throw in a K&N and get oil on the AFS and they would die even faster! I had an Amsoil filter in the 98, saw no difference at all. Now all my engines get stock air filters.

 

[BILLVO]

Towpro



I have an 03 jetta "I studied on tdi website before getting it" I wanted the updated timing belt drive setup for the 100k change versus the 02 and earlier 80k changes. Mines a 5spd manual loaded, everything but heated seats and traction control. Wish I would have found a passat "For the extra room" but this was hard enough to find. 43 mpg overall at 70-75 mph.

 

[TowPro]

When we bought the Jetta V, we first drove the passat, the Jetta won hands down! the passat in 05 (maybe it was an 04 left over) had a 2L diesel, but the Electronic power stearing on the Jetta makes it so nice to drive on the crowned roads where I live, plus the traction control has been more then I expected for driving in the snow. The Jetta V has been the best VW we have ever owned. In fact it is already slated to become my Daughters car in a couple years.