2001 Jetta TDI repair

[Daox]

My wife and I replaced the front brake pads on the Jetta last night. The passenger side slide froze up and ate the outer pad up so we re-lubed all the slides as well. No pics as it was cold and we just wanted to get it done.

We also threw in a new air filter.

I still have rear pads on the way. That is the last mechanical fix for the car really. I still gotta clear coat the rear quarter panel and I want to 3d print some new radio knobs as she is missing a bunch of the small ones.

[Daox]

The rear pads and new rotors are on the car.

So, I fired it up last night and I got a few engine codes:
P118 - coolant temp high
P228 - high TPS signal
P234 - turbo overboost condition

I figure the first two have to do with wiring and/or me not plugging everything in. I'm not sure on the turbo thing. Perhaps a vacuum line got missed.

I also found out the clutch pedal is not quite right. It doesn't come up off the floor as far as it should. So, something isn't right there too.

A few more issues to iron out. Tips appreciated.

[Xist]

Obviously, your computer is confused, and trying to tell you to focus on the Metro, whose turbo is definitely not overboosting! I would go as far as to say it is not boosting at all!

[deejaaa]

no tips from me but mine is still in the shop.
was told it ran better with exhaust removed. took it home, cut open the cat and saw this:



this was the entrance side of the cat. exit and center was still clear, even after almost 300K miles.
not sure if this was a cause or effect.
stitched it back together and will drop it off at the shop.

[Daox]

Doh, that'll do it!

I worked on the Jetta again last night. I hooked everything back up (forgot I hadn't plugged the glow plugs in after testing them) and fired it up and only got check engine lights for the glow plugs this time. This was a problem before the swap, so I figure its a problem with the harness. I did check the resistance on the plugs and one of them is off (about 13 ohms), but the others are fine (around 4 ohms).

The clutch pedal problem was odd. The pedal was just stuck down and didn't fully return. However, once I pulled it back up (with little force) it worked perfectly. Yay, super easy fix.

So, now my final problem is that it won't shift into reverse. I have all the other gears, but not reverse. When you go to put it in reverse, it just goes into 1st (tested by trying to drive it backwards and it goes forward), even though it does go the extra bit over. I had my wife shift the car for me while I watched the transmission linkages. It looks to be working properly but perhaps just isn't moving quite far enough? So, I'm thinking it either needs adjusting or just needs to be worked a bit as it is VERY stiff and hard to move the shifter from side to side. I assume this is just from sitting so long.

[kafer65]

Eleven ohms is pretty high on the plug. Harness is probably a good educated guess too. I had intermitted problems shifting when my dual mass flywheel springs were spinning around and jamming the throw out assembly. Also, on my 06 there was a Utube vid on how to reset the shifter assembly cable ends that was very helpful when I got jammed into 5th gear once. I'm not sure that applies to your year

[Daox]

I have finally finished up the Jetta and fixed the reverse problem. I had to disconnect the shift cable, work the shifter rod up and down in the transmission with a pry bar to pull it up, and a hammer to push it back down. It slowly loosened up until I was able to actuate it by hand. After that, I still had to adjust the shifter linkage as it still wouldn't push the linkage quite far enough. Now, it goes into reverse silky smooth.