98 TDI Beetle woes
Just a note to address issues on my 98 TDI Beetle. I have had the problem with a clogged intake manifold that cost 1,000 to fix. I was told by the service manager at the dealer that this is a common problem with the TDI cars. I feel that it is an inherent desighn flaw and should be covered byVW. I also just got the price fpr parts on a new clutch. Evidently the clutch system is unlike a typical clutch pressure plate system and is of course about 7 times as expensive as a clutch kit for a gas 2.0 or almost any regular car. This engine puts out less HP or torque than a 5 liter mustang but thr clutch costs 5 times as much. The timing belt replacement cost and interval should turn off anyone that is foolish enough to buy one of these cars because of mileage. The fuel savings when offset by the cost of maintaining this car and the little annoying glitches negate thecute novelty and stinky hands at fill up time. I am a mechanic, life long VW nut, diesel nut and my next car is a HONDA!
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297 Said,
August 26, 2004 @ 12:00 pm
98 TDI Beetle woes – I would find someone with a VAG-COM to modify disable EGR and prevent another clogged intake manifold.
Actually, if you’re a mechanic and a VW nut, I’d say you should invest in your own VAG-COM, If pays for itself very quickly, and with it, you can prevent a clogged intake manifold yourself.
I am not aware of the TDI having a crazy clutch or tranny… I pretty sure it has the same transmission as the 2.0L and 1.8L, the 02J. But seeing as you’re a mechanic, why not put in a slightly bigger clutch with a lighter VW-OEM flywheel? It costs less than the replacement.
297 Said,
August 26, 2004 @ 12:00 pm
98 TDI Beetle woes – Screwed up my post.
Anyhow, I am not aware of the clutch being anything special, other than having a dual-mass flywheel. Since you’re a mechanic, you might want to consider installing a better clutch for cheaper, like a slightly larger clutch with a single-mass flywheel, from ECS Tuning.
Will Said,
August 28, 2004 @ 12:00 pm
98 TDI Beetle woes – Thanks for the tip. I am checking on the clutch that you recommended. I am in California and my car is in Florida and I have not been able to really look into the clutch problem. If I was home I would do the replacement my self but I have to get the car back on the road and have a mechanic doing it for me. P_lease explain the way to disable the EGR to solve clogging problem. I am aware of some people doing some mods to solve this problem but I have been out of town since the manifold cligged and have not been able to research. I thank you for your reply and knowledge. Will
297 Said,
August 28, 2004 @ 12:00 pm
98 TDI Beetle woes – You can disable EGR using a VAG-Tool to connect to the car’s ECU and toggling a stored value, basically a software switch. The procedure is detailed here.
Ross-Tech reverse-engineered the VW VAG-Tool used by dealer service centers and sell it as VAG-COM. If you are a mechanic and work on VW, Audi, SEAT and Skoda vehicles, it’s probably worth your while to purchase it. Otherwise, you can just find someone near you with a VAG-COM who’ll do it for pizza and/or beer: TDIClub VAG-COM List.
I have the ECS Tuning Stage 1 clutch kit myself. The flywheel is single mass, and it does tend to rattle slightly in neutral, but it’s 3/5 the weight of the stock flywheel, and the Sachs clutch is the one used in the VR6, with more surface area at 228mm diameter.
paul Said,
August 30, 2004 @ 12:00 pm
98 TDI Beetle woes – got your reply “check engine light again and again..” Thanks. I don’t see how economy car ad VW go together. It’s becomming an oximoron. I hear BMW has a great offer on service. rumor is that you only buy tires after the original purchase – EVERYTHING else is part of the warranty. I’m going to go look into it. Moral of story, dump your TDI after 5 years unless you are a mechanic.
297 Said,
August 30, 2004 @ 12:00 pm
98 TDI Beetle woes – Actually, and this is a sad thing, VW no longer wants to be an economy car company. The Phaeton and Touareg are the first generation of a luxury line.