Got a new car

Well I did it.  Bit the bullet and, after thinking about lots of different possibilities, decided to go with what I know:

2013 VW Golf TDI with tech package.  It took me a while to find one, but as I learned from my last car, if you don't get what you want the first time, you'll spend the rest of your ownership trying to add it (and in many cases you still won't get it).

Here are some of the many features:

• Heated seats (my previous car didn't have this and I regretted it for 12 years.)
• Xenon headlights with "follow" action
• LED DRLs
• 17" rims
• Dual power seats
• Nav, SDcard slot
• Bluetooth smartphone integration
• Sunroof
• DSG transmission (basically a standard transmission that is robotically automated)

It's going to take me a year or two just to get a handle on what is in this car.  I apparently have the RNS315 radio, which is different from the RNS516, but is apparently now standard on the tech package, I'm guessing because it's a little cheaper(?). This is the kind of stuff I am dealing with.

The only mod I've done so far is to rewire the lighter outlets so they are "always hot".  The new VW's have apparently finally gone to the dark side of shutting off the 12V outlets when the key is off.  It was driving me absolutely bonkers because every time I turned the car off my phone would reset, not to mention the fact that the battery wouldn't charge unless I left the ignition on.  I don't understand how the rest of the world can tolerate this.  My guess is that all the car manufacturers have gone to this standard because a few people managed to keep killing their car batteries, or starting fires.  Luckily it was pretty easy to rewire - no cutting wires, soldering, or even removal of any trim.  I am thinking about putting out a kit on eBay in case anyone else wants to do this.  If this sounds good, please let me know so I can gauge the interest level.

I'll be posting in the future with more details, but here are my (really) early impressions:

• It's fast, but laggy (stomping it from stop = almost 3 seconds delay before launching)
• Handling, on the other hand, is amazing - responsive yet very refined
• Car tech has come a long way in the 12 years since I bought a car.
• God help me if I ever have to fix this thing.

And for anyone who has this question on their mind, no I'm not planning to convert it to run on SVO. 

My 2002 Golf is for sale. It is clean, and, of course running the best it ever has.  I will miss it (almost as much as I will miss not having any car debt).  But I will have a LOT more free time. 

Emergency repair after brake caliper cease

Happened a little while ago now, but I didn't get a chance to write about it.  The driver's side brake caliper had been dragging for quite some time.  After a trip the wheel would be extremely hot.  I'd been planning to deal with it some weekend, but when I noticed some brake fade, I had to do something.  I ordered a new hub on a hunch, and it turned out to be a good call.

Driver side rear end torn all the way down after the components were damaged from high heat.

The caliper pins had frozen up causing the brake to be stuck on.  The pads were worn down to nothing.  The heat caused the tone ring (associated with the ABS sensor) to warp.  Since the tone ring is integrated with the hub, I had to replace the entire hub assembly.  

While I was in there I also replaced the splash shield (shockingly, the dealership had this item in stock!  The first time ever). So the whole process went like this:

• Remove wheel
• Remove brake caliper
• Remove rotor
• Remove hub nut (after locating my old VW hub nut socket!)
• Pull hub assembly (used jaw pullers)
• Unbolt stub axle
• Get the &*@#$!ing bearing race off without damaging the stub axle (I used air chisel.  It was fast but delicate work.)
• Replace splash shield
• Reinstall stub axle
• Install new hub
• Install new hub nut
• Reinstall rotor (it was only a little warped, acceptable).
• Repair and grease caliper pins
• Reinstall caliper
• Install new brake pads
• Install wheel

I did this all in under 2 hours, as I needed to get my car back on the road in a hurry so I could return the trailer I had borrowed.  Then I finished building a deck. 

On a philosophical note.

I've spent a lot more time this summer working on my house instead of the car.  The work wasn't really that hard (I didn't have to figure out how to drill out a single rusty bolt), and now we have a beautiful kitchen and a new deck.  I have a great feeling of accomplishment and something that I can share with our friends and family.  Really got me thinking. If I put half the amount of labor I put into my car into my house, I would end up with something that is actually worth money in the end.  Meanwhile, my car just sucks money and time and, if I'm lucky (and determined enough), I am left with a car that will get me around.  I looked at my car log, and the amount of money I've been putting into it for parts alone would pretty much justify the payments on a $20K auto loan.  Add to that the fact that I'm really getting tired of dropping everything so I can lose an entire morning, afternoon, day, or days working on my 12-year-old car.  Even though I love my car, I think the time has come for me to trade up to something that I can "just drive".  When I got my Golf TDI, they were very difficult to come by, but the new ones are pretty easy to find and absolutely drool-worthy.  I've also considered getting a Prius, as they are loaded with tech opportunity.  They get similar mileage, but they run on gas which is cheaper than diesel (at least it has been for about 10 years).  I wouldn't have the option of running on vegetable oil, but it's been quite a while since I've done that, and I probably won't have time to do it again.

Anyway, just something I'm considering.  I'm not in a hurry to do anything yet, and as it happens it looks like the crop of cars I found interesting on Craigslist has sort of dried up.  Meanwhile. my inspection is due and I have a coolant temp sensor to replace.  So for now, tune into the next episode!

Euro Projector Headlights and Kamei Grill for the Golf

Woohoo!  I got something done on my car.  Had to go in yesterday and tighten up the connection between the counterweight and transmission gear selector (it came loose, probably was not torqued well enough when I replaced the transmission).  I decided, while I have the battery out, might as well take off the bumper and replace the headlights and grill.  This job ended up being a lot easier than I thought, because I had left the wiring there for my old custom fog lights.  Headlights are halogen projector type with OEM-style marker lights AND LED angel eyes.  I wired the angel eyes to a switch under my dash so I can turn them on/off, depending on how fancy I want to be.

I can't wait to be able to see where I am going at night.  My old headlight lenses were so scratched up that the beam was diffused.

200K mile rehab saga: Good news from Volkswagen of America

Just a quick update, after about 6 months of waiting (and some back and forth), I
finally heard back from VW body shop- my fenders have been approved for replacement under the corrosion warranty! I am so psyched :)  They will follow up next week to make an appointment, etc.  I had pretty much lost hope!

New regulator for alternator, e-bike riding after battery drama

I replaced the regulator in the alternator.  The VW MK4s have a module complete with the brushes and everything, so if you replace this module, 90% of alternator problems are cured.  Unfortunately it was a very tight space and it took me a couple of hours to get to it, but now that it's done, it works.  I uncovered a different way of getting to it, which I posted on the TDIclub.com forum.  Happy to have my car back in action.

I have been working on the appearance update for the car.  I received my new front grill, which I painted:

New Kamei front grill which I painted silver, before clear coat

It looks great, I think it will be a nice improvement for the car.  I also got my new headlights, they are projector style with halo DRLs.  I haven't looked at them a lot, but I think they will look nice.  Lingering concerns involve difficult (running of all the extra) wiring, and more difficult bulb change access.

Still waiting to hear back if my fenders are covered by VW, so I haven't been rushing head-long into disassembling the front end.  However, we are supposed to get a lot of rain over the next week or two, so I may pull the car in for an indoor project.

I've been riding my e-bike again!  After all the battery manager drama, I was anxious to get some numbers so I could find out how much damage the battery took.  Throughout several trips over the last week.  I started a log book so I can keep track of battery performance.  So far I've had one trip where the battery was looking pretty strong - sitting at 52.5v after a good 20 mile trip that used ~10 AH:

Looking good after a 20 mile round trip.

...and one where it died and cut out at about 14.5 AH, 72% of what its original capacity was - so, not so good.  I charged up the pack and it seems to have rebalanced itself, so I'm guessing my next trip will be pretty good.  The #1 cell likes to drain itself, so I think if it comes off a fresh charge, it will be strongest.

Been making a few trips out to the beach to drop off these critters:

This little dude just qualified for a free e-bike ride!

They have been getting into the garage lately and apparently making a home in there.  So I trapped 2 of them and brought them over 5 miles away, as apparently they have a pretty good homing range.

What broke today

I just realized I could pretty much title every blog post with above, or better yet, change the name of the whole blog to it.  Ha ha(!)

Yesterday I cleaned up the car a lot.  Finally got a chance to go to the car wash, and I pressure washed the engine bay.   I know, I know, always a little risky for electrical problems, but I've done it before and never had any problems.

Anyway, we get in the car to go home from a friend's house. I start the car, glance down and notice the alternator light is on.  I hook up my radar detector (a Beltronics Vector V995, an awesome machine with a bonus voltage readout, totally brilliant!), and sure enough, it's about 12.1v.  No alternator output.  Since child is now screaming, I shut off the headlights (still a little before dusk, so okay) and make for home.  On the way, the alternator output flicked on and was okay for the ride home.  This morning it seems to be down for the count.  I wiggled all the wires, and it doesn't seem to be a loose connection, so it must be the alternator.  It's a Bosch alternator with a separate regulator, with most of the wear items built into this replaceable part.  I found one on eBay for $22.  Next project will be to get the alternator out, change the regulator, and reinstall.

Some good news.  Yesterday I also visited the dealership and showed them my rusted fenders in the hopes that it might be covered under the 12 year, unlimited mileage, corrosion protection warranty.  There was a TSB release specifically addressing the rust areas I have.  The guy at the body shop took some photos and said it was "up to Volkswagen", but he thought it should be covered.  I'll find out in 2-4 weeks.  If I can get those fenders replaced, it will be a major step in the 200k rehab program crossed off the list.

Kind of looking forward to posting something other than car repair, but that's what I'm dealing with right now.

Drive fast and stay close to the break down lane.

The Golf's 200K Rehab

Now that my car has rolled 200K, and I've decided the budget doesn't allow me to by my dream Golf anytime in the near future, I've been thinking about doing some other fairly serious rehab.  Over the last 11 years, there have been a lot of things that broke, rusted, burnt out, collected, or what-have-you in and on the car, and I think it's time to address a lot of it.  Since I drive this car so much, it has a chance to really improve my life.  The older I get, the more I realize investing time and money into things you use the most is time/money well spent.

So starting today, here's the partial list of rehab items as they came spewing forth.  I will be adding to this list as I think of things.

Exterior

• Headlight lenses
• Kamei mesh front grill
• Rear spoiler
• Rust repair - Fenders, hood, trunk, above windshield

Interior

• Clean out glove box (remove tapes)

• Fix rear defroster
• Tint windows
• Steering wheel

• Design custom console around shifter/e-brake handle to house:
• Triple 12V outlets & Remote for radar detector
• OBD port
• Inverter
• Bluetooth receiver
• Aux jack
• Phone?

• Permanent install/wire routing:

Radar detector

12V Triple outlet

12V Cooler

Bluetooth

Phone power

• Driver side blown speaker
• Driver side door switch
• Trunk courtesy light
• Install 12V cooler and 120v inverter

Engine

• Pressure wash engine bay
• Fix veg fuel line
• Replace veg filter
• Skid plate/Belly pan repair

On the road again

We had a big trip coming up, so I managed a last minute push and got the transmission in.  Finished Tuesday night, including front brakes rotors and pads, and new tires.  Trip started Thursday. 

The car has been preforming very well.  The new transmission is awesome - very quiet. I even managed to do the 5th gear swap, which was much harder to do on the new transmission. It took a lot more force to get the gears off  for some reason, I had to buy a new impact wrench and modify a new gear puller on the bench grinder. Seriously, I think I spent an extra 4 hours on this (including trips to the store for tools).  I probably had it easy with my old, worn out transmission.

The Veggie Golf rides again!

First leg of the trip saw 46.2 mpg - lower than I'd hoped, but not bad when I consider how much idling with the air conditioner on we had to do (while feeding the baby).  Also, part of that leg was done with my snow tires and roof rack on. 

The round trip mileage was 819 miles.  So I guess if I was going to have a problem, I probably would have noticed it by the end.  All looks good.  Next project, make it look respectable again.

Another day, another transmission job

Sometimes it feels like it never ends.  But nonetheless, another day has brought forth another chapter in my struggle to have a perfectly working car.  So let's get down to it.

The Probe awakens early from its winter nap

Well just when I thought I'd finally gotten past this auto maintenance nightmare... What was only supposed to be an exciting couple of weeks in incoming baby-world (my wife is due next weekend), I have spent basically dealing with my cars.  I'll try to summarize the story as simply as possible.

Seal replaced, back on the road!

Last night things moved ahead considerably.  I was very happy to see that the replacement seal arrived priority mail (from idparts.com - they've never done me wrong) on Monday, after I ordered it on Friday night.  I also went out and found a seal puller (similar to the one pictured) at Sears, of all places.  None of the regular auto parts stores carry this thing for some reason.

The elusive seal puller I finally obtained.

Torn up gears, and a dead end for now

Well today I got the transmission cover off.  There were two gears in here (5th gear and the selector gear) that were totally rounded (all teeth were sheared off).

Leaky Transmission

Well after a horrible stay at La Guardia airport for almost 12 hours, I am home and thinking about my car problems.  Tried to get into it after work today, which usually goes something like this:

Bye Bye, 5th Gear

It had to have been within 10 minutes of my staring at the odometer, marveling at the nearly 199,000 miles I had wracked up on my VW Golf and thinking how trouble-free the car had lately been, when my cruise control disengaged, and the car started to do the all-too-familiar "death coast".  Without thinking or trying anything else, I immediately turned on my four-way flashers and started moving into the breakdown lane -scoping the distance to the next rest area.

Diesel Haulin'

In the final days before the snowstorm, I managed get my act together and squeeze in the acquisition of half a cord of wood.  

Pre-Winter, Auto Mechanic Intermission

I've been fortunate to have had a pretty long break from playing home auto mechanic, but lately things have been wracking up quite a bit, and for a number of reasons, I had to take action.  The most recent project was on my 2002 VW Golf TDI (for more about this car, you can have a look at my old blog, Veggie Golf).  I was going to hold off, but the oil building up in the driveway was an indication that I really needed to get on it.

Items to fix:  Leaking cam seal, timing belt replacement (maintenance interval reached), rear brake rotors and pads, and a few other odds and ends.  When I got into the timing belt cover, it was pretty clear the cam seal was doing very little to keep the oil in the engine.

This is the lower timing belt compartment after I cleaned it up a lot. 

Any doubts were sufficiently quelled when I drained the oil from the crankcase, and got about 2 qts. max out of it.  This is dangerously low, especially for a diesel, and even more especially for a turbo equipped engine.  Feeling lucky, I went ahead and ordered the parts for the timing belt change, including belts, tensioners, and bolts.  Most of the operation went pretty smoothly, although I don't remember ever having so much trouble getting the engine mount bracket in/out.  I probably spent about 2 hours screwing around with that thing alone.

The new cam seal went in pretty easily.  The old one didn't seem damaged, but rather appeared to have come unseated from the camshaft somehow.  I didn't spend too much time worrying about it, but I paid close attention to how I put the new one on.  All back together now, have to pressure wash the engine bay and then off to the muffler shop to fix the broken flex joint, which is causing exhaust to go into the car.  All told, probably about a 10 hour job for me (I'm definitely out of practice).