[Burnitwithfire]

The DIY thread, bigger and better!!!

The DIY thread, bigger and better

Let me know if pics stop working in a thread, if a link is broken or sending you to the wrong place.

You're encouraged to post links to any DIY.

I am in no way held responsible for any damage caused by the use of these DIY's, USE AT OWN RISK! I also did not make all these DIY's. Have fun!

• Holistah's original DIY thread
• Official MK2 forum FAQ
• Old MK2 FAQ/DIY thread
• AA1Car Automotive Repair & Diagnostic Help
  (Lots of good info on general mechanic and diagnostic, not VW specific
• A2 Ressource
  Maintained by our very own VDub2625
• Most ghetto fix thread Because not all DIYs are good
• The Definitive Cheap A$$ Build Up LOTS of free/cheap tuning tricks
• How to use the Vortex SEARCH function, tips & tricks

Table of contents

• Interior
• Exterior & lighting
• Engine & engine bay
• Brakes, steering, suspension, wheels, tires & transmission
• Miscellaneous & online parts links

Interior

Dash & center console

• Blower motor resistor fix
• Dash emoval
• Corrado dash swap 1
• MK3 dash swap 1
• MK3 dash swap 2 Dead pics
• Mk3 center console mod 1
• MK3 center console mod 2
• Ford Taurus cupholder mod
• Cupholder Mod
• Center console stereo install
• Working blank/dummy switch
• Dash blank/dummy voltage meter
• Custom Ipod bezel mount
• Custom shifter frame
• MK4 shifter & boot

Doorcards, headliner & general upholstering

• Headliner reupholstering 1
• Headliner reupholstering 2 Dead pics
• Headliner reupholstering 3 Dead pics
• Headliner reupholstering 4
• Headliner clips
• Golf headliner in a Jetta
• Complete re-do of door cards Dead Pics
• Door cards reupholstering
• Rear parcel shelf and speaker tray carpeting Dead pics
• Custom made rear parcel shelf
• Door speaker mod
• Reinforcing door speaker grilles

Gauge cluster

• Gauge cluster removal
• Odometer fix
• Custom gauge faces
• Gauge cluster lighting
• Gauge cluster LED 1
• Gauge cluster LED 2
• Digifiz gauge cluster info 1
• Digifiz gauge cluster info 2
• Digifiz gauge cluster info 3
• Gasser tach conversion to diesel tach
• Changing the clock from 24h to 12h

Heating

• Heater core replacement 1
• Heater core replacement 2
• Heater core replacement 3
• Heater core replacement 4 Very funny read
• Heater box blend door foam fix

Interior lighting

• Heater controls LED 1
• Heater controls LED 2 Dead pics
• Heater controls LED 3
  Best one yet
• Heater controls illuminated siders
• Headlight switch LED
• LED panel dome light

Seats

• Recaro bottom support fix 1
• Recaro bottom support fix 2
• Recaro bottom support fix 3
• Recaro side bolster replacement
• Recaro restoration
• Recaro disassembly/reassembly
• Self reclining Recaro fix 1
• Self reclining Recaro fix 2
• Leather seat re-dying 1
• Leather seat re-dying 2
• MK3 seat swap
• MK4 seat swap
• New Beetle seat swap
• Seat fabric repair
• Corrado rear seat install

Sunroof

• Electric sunroof mod 1 Dead pics
• Electric sunroof mod 2
• Electric sunroof mod 3
• Tilt and slide sunroof

Water leaks

• The water leak thread
• Vapor barrior replacement
• Vapor barrior FAQ

Other stuff

• Ignition switch replacement
• Removing the lock cylinder from the ignition housing
• Three point seatbelt swap
• Big spline steering wheel adapter removal
• Steering wheel turn signal tab fix
• OEM steering wheels that fit MK2's
• CE2 wiring harness info
• Opening stuck rear door
• Grip tape pedals
• Ignition lock rekey
• DIY remote locking system
• Ipod only audio (no head unit)
• Fiberglass sub box
• Noise reduction

 

[Burnitwithfire]

Exterior & lighting

• Interior
• Exterior & lighting
• Engine & engine bay
• Brakes, steering, suspension, wheels, tires & transmission
• Miscellaneous & online parts links

Exterior & lighting

Bumpers

• Shaved bumper 1
• Shaved bumper 2
• Shaved bumper 3
• Euro small bumper installation
• Small bumper removal
• Big bumper removal
• Bumper reblackening 1
  (Kiwi dye, paint, heatgun and back-to-black)
• Bumper reblackening 2
  (Heatgun method, video included)
• Bumper reblackening 3
  (Duplicolor trim paint)
• Bumper reblackening 4
  (Krylon Fusion paint)
• Passat bumper spoiler

Door handles

• Door handle swap
• Door handle removal
• Porsche door handle swap
• Audi style door handles
• Door handle de-locking
• Door & Trunk lock rekey
• Sloppy door handle fix
• Door handle reblackening
  (Krylon Fusion paint)

Grilles

• Bagdeless grille 1
• Badgeless grille 2 Dead pics
• Badgeless grille 3
• VW emblem relocation on grille

Headlights, foglights & relay harnesses

• Daniel Stern Lighting
  (LOTS of info about automotive lighting, relaying, HIDs, E-codes...)
• MK2 foglights with MK3 housing
• Twist in city lights Dead pics
• Headlight relays
• Headlight conversion 1
• Headlight conversion 2
• Rallye headlight conversion on aero rad support
• OEM & aftermarket Rallye rad support comparison
• Headlight smoke
• Headlight tint
• ECS MK1 5x7 projectors on westy front end
• Fog/driving light installation (Page 13, 1/4th down)
• Westy headlights info thread
• BMW ellipsoid projector retrofit into a 7 round
• Foglight wiring
• Front and rear foglight wiring
• Foglights on with parking lights
• Crimps and butt connectors

Taillights & turnsignals

• Turn signal FAQ
• LED spoiler brake light
• Euro Jetta taillights (1/2 down the page)
• DIY clear turnsignals
• Taillights tinting 1
• Taillights tinting 2
• Taillights tinting 3
• Taillights tinting 4
• Taillights renewal
• LED mirror blinkers

Wipers

• Rear wiper mod
• Single/mono wiper 1
  (Sketchy english but it's Max and we love Max)
• Single/mono wiper 2
• Single/mono wiper 3
• Scirocco single wiper
• MK3 programmable wiper relay

Other stuff

• Fender rolling
• Fender rolling
• Sunroof gasket replacement
• Renault Twingo ragtop
• Mirror delete plate
• Wide fenders Dead pics
• Jetta style tailgate
• Rare MK2 front ends
• Restoring faded paint
• Quick polishing guide
• Thule roof rack infos
• How to safely remove window tint
• Door & fender trim clips and grommets (More info at bottom of thread)
• Drip rail replacement with universal seal
• Lower windshield Frame/cowl panel replacement

 

[Burnitwithfire]

Engine & engine bay

• Interior
• Exterior & lighting
• Engine & engine bay
• Brakes, steering, suspension, wheels, tires & transmission
• Miscellaneous & online parts links

Engine & engine bay

FAQs

• Engine oil FAQ
  (not VW specific)
• Engine oil additives FAQ
  (not VW specific)
• Fuel & engine FAQ
  (not VW specific)
• 8V FAQ
• 16V FAQ
• Forced induction FAQ
• Watercooled engine codes & specs

Alternator & belts

• 8V waterpump replacement and AC delete
• Audi A6 alternator on a 16v
• 16V alternator relocation
• Serpentine belt setup on a 16V
• V-belt splash guard info
• Replacing voltage regulator

Diesel

• Diesel: smoke color summary
• Diesel: governor mod
• Diesel: 1.6l headgasket upgrade
• Diesel: more power from your 1.6TD
• Diesel: Timing the injection pump
• Diesel: Better glow plug wiring
• Diesel: Rebuilding your injectors

Engine bay

• Windshield washer bottle relocation
• Lightweight battery install
• Hiding wires
• Simplified engine bay
  (not a DIY per say but it has a lot of good stuff)
• Engine bay detailing
• Engine bay shaving discussion
• Shaved bay picture thread

Engine management & chips

• OBD2 port mod
• 8v Megasquirt info
• Digi 2 to digi 1 info
• Motronic 16V chips
• VR6 Ford coilpack conversion

Engine mounts

• Hockey puck front motor mount 1
• Hockey puck front motor mount 2
• Transmission mount
• Rear engine mount
• Making your own poly mount inserts

Exhaust

• Picking an exhaust
• Exhaust repair
• Dual outlet exhaust manifold swap (8v)
• MK3 exhaust manifold on 8v
• Downpipe clamp trick
• O2 sensor how-to Dead pics

Swaps

• VR6 swap guide
• VR6 swap using MK2 cluster
  (coilpack VR only)
• VR6 timing chains
• ABA bottom end swap
• ABA swap info 1
• ABA swap info 2
• 1.8T Swap FAQ
• 1.8T swap info 1
• 1.8T swap info 2
• 1.8T swap info 3
• 16VG60 info
• 16V intake manifolds

Valvetrain & porting

• 16V camshaft installation
• Intake manifold port and polish
• Standard Abrasive's guide to P&P
• Standard Abrasive's guide to engine block prep
• Homemade valvespring compressor 1 Dead pics
• Homemade valvespring compressor 2
• 8v head cut-out

Other stuff

• Starter Repair/Replacement
• Open element/cone air filter
• Rusty battery tray replacement Dead pics
• How to use Seafoam
• Horn replacement
• Passat B3 fan shroud swap Dead pics
• Compression ratio calculator
• Pulley and belt calculator
• CE2 wiring FAQ
• Walbro fuel pump
• Intank fuel pump replacement 1
• ISV disassembly
• Custom catch-can
• OEM oil cooler delete
• Milky residue on the oil cap

 

[Burnitwithfire]

Brakes, steering, suspension, wheels, tires & transmission

• Interior
• Exterior & lighting
• Engine & engine bay
• Brakes, steering, suspension, wheels, tires & transmission
• Miscellaneous & online parts links

Brakes, steering, suspension, wheels, tires & transmission
FAQs

• Steering FAQ
  (not VW specific)
• Suspension FAQ
  (not VW specific)
• Brake FAQ
  (not VW specific)
• Wheel & tire FAQ
  (not VW specific)
• Suspension forum FAQ 1
• Suspension forum FAQ 2
• Air suspension FAQ

Brakes & bearings

• Front wheel bearing tips
• Front wheel bearing replacement
• Front discs & pads replacement
• OEM front brake upgrades
• Big front brake swap
• Rear disc brakes swap
• Rear disc brakes maintenance
• Rotor screw removal
• Brake proportioning valve adjustment
• Hard brake line lenghts
• Hard brake line repairs
• Caliper rebuild Dead pics
• Homemade pressure bleeder 1
• Homemade pressure bleeder 2

Front & rear shocks/struts/springs

• Front & rear shocks replacement
• Front and rear shocks replacement without air tools
• Fixing clunky shocks
• Ground Control camber plates
• Hot to tell if you have rebuildable front struts
• Rear shock circlip fix
• The stance thread
  (Not a DIY but very informative on different suspension setups)

Steering

• Manual steering rack replacement
• Quaife quick ratio steering rack
• Tie rod replacement
• Ball joint replacement
• Power steering rack looping
  (manual steering using a looped power steering rack)
• VR6 power steering pump replacement
  (It's for a Passat B3 but it should be good for a swapped MK2)

Struts & swaybars

• Homemade rear strut brace
• Homemade rear strut bar
• VR6 sway bar installation (1/4 down the page)

Tires & wheels

• Falken ZE-912 VS Sumitomo HTR-200
• Tire weight VS good grip
• Wheel refinishing
• Multi-piece wheel refinishing 1
• Multi-piece wheel refinishing 2
• Wheel offset calculator
• Bolt pattern reference (covers most makes)
• Tire size calculator
• Hub centric adapters
• 4x100 to 5x100 hub drilling

Transmission

• Hard to find transmisson part
• Transmission FAQ
  (not VW specific)
• Anything related to the 020 transmission
  (gear oil change, teardown & rebuild, 5th gear swap and much more) Maintained by Broke
• Reduce/eliminate gear grind
• Automatic to manual tranny swap
• Shifter bushing replacement 1
• Shifter bushing replacement 3
• Shifter bushing replacement 4
• USRT Smart Shift kit install
• Missing linkz VS USRT
• O2J cable shifter conversion 1
• O2J cable shifter conversion 2
• Starter bushing replacement
• Clutch replacement
• Hydraulic clutch bleeding
• Short shifter
• 020 and 02A speedo cable hybrid

Other Stuff

• Rear control arm bolt fix
• Subframe bolt fix 1
• Subframe bolt fix 2
• Installing rear beam alignment shims
• CV boot and axle replacement

 

[Burnitwithfire]

Miscellaneous & online parts links

Table of contents

• Interior
• Exterior & lighting
• Engine & engine bay
• Brakes, steering, suspension, wheels, tires & transmission
• Miscellaneous & online parts links

Miscellaneous stuff

• Vagcat (online ETKA) (requires FREE registration, very good source for part numbers, includes schematics just like ETKA)
• Dealer parts & price locator (requires FREE registration)
• Calculators and converters (More calculators and converters you can handle!!!)
• Speeding facts and myths
• MK4 style switchblade key
• Photography tips
• Alarm system installation
• Jacking points
• OEM parts that are a cheap upgrade
• MK3 & MK4 parts that are an upgrade
• Junkyard tuning 1
• Junkyard tuning 2
• The VW dictionary
• Chinese MK2: parts list, numbers and prices
• Rare MK2 parts thread
• MK2 part number thread

Online parts links

• The list
• The updated list
• Misc clips, fasteners and grommets

 

[Burnitwithfire]

Reserved, sorry for the multi-posts but the forum has a word limit for every post which prevents me from doing it in one single post

Modified by Black Smokin' Diesel at 1:17 PM 1-18-2009

 

[fullmetalrabbit]

Re: (Black Smokin' Diesel)

Nicely done....should sticky this.

 

[travbrack]

Re: The DIY thread, bigger and better!!! (Black Smokin' Diesel)

Perfect. The FAQ needs to link to this for sure

 

[yerigga]

Re: (fullmetalrabbit)

nice, u must have a lot of time into making this thread. this well help alotta people find those dDIYs they cant find.
thanks i'm sure it will come in handy for me http://****************.com/smile/emthup.gif

 

[Burnitwithfire]

Re: (yerigga)

Quote, originally posted by yerigga »

nice, u must have a lot of time into making this thread. this well help alotta people find those dDIYs they cant find. thanks i'm sure it will come in handy for me http://****************.com/smile/emthup.gif

Well Holistah did most of the work back then. It did take a few hours to get everything sorted out and cleaned. I'll keep this updated as often as possible.

 

[ratdub]

Re: (Black Smokin' Diesel)

thank you for posting a revised diy thread http://****************.com/smile/emthup.gif

 

[DubbinChris]

Re: (ratdub)

Very cool of you to do this. Even cooler to find a link to one of my threads.

 

[retroron]

Re: (DubbinChris)

saving this one thanks http://****************.com/smile/emthup.gif http://****************.com/smile/emgift.gif

 

[flippinvws]

Re: (retroron)

this is the best thread in quite some time......
http://****************.com/smile/emgift.gif

 

[DubbinChris]

Re: (retroron)

MKII part number thread link take you to the rare parts thread....can you fix this?

 

[brandonrosensteel]

Re: (Black Smokin' Diesel)

Amazing! Thanks so much in advance. http://****************.com/smile/emthup.gif
Now that this information is available, I'm sure my Jetta will break more often.

 

[mk2jettarunner]

YAY!

 

[Nintendo]

Re: (mk2jettarunner)

Good job http://****************.com/smile/emthup.gif

 

[fullmetalrabbit]

Re: (Nintendo)

Is there a way to get in touch with the original posters and fix up the dead pics? Just a thought.

 

[morimori]

Re:

Quote, originally posted by Nintendo »

Good job http://****************.com/smile/emthup.gif

http://****************.com/smile/emthup.gif http://****************.com/smile/emthup.gif