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    1. Member Charles Devine's Avatar
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      03 Jetta GLI 24V Manual | 09 GTI 2.0T TSI DSG
      05-01-2014 11:08 AM #1
      Hello everyone, by the time I'm done with this hopefully you all will have learned something from me or just enjoy my car as much as I do. The entire point of this thread is to keep a timeline of when I purchased this beaten up 02 GLI 24V that needed some love. This thread will be slow and tedious unlike most of your other build threads.

      INDEX
      INITIAL CLEANING AND REPAIR
      04.5+ CONSOLE INSTALL/SWISS CHEESE AIR BOX
      PILLARS REMOVED/RUINED HEADLINER
      TIRES/BUSHING DAMAGE/HEADLINER REMOVAL
      SUNROOF SHADE BARE
      HEADLINER PREPERATION
      PLASTICS PAINTED
      A PILLARS REDONE
      C PILLARS REDONE
      B PILLARS REDONE
      B PILLARS COMPLETED
      ENGINE COVER
      SHARK FIN ANTENNA INSTALL/REVIEW
      HEADLINER ATTEMPT SUEDE
      MFA WIPER STALKWIRING DIAGRAM
      R32 CLUSTER INSTALL
      SUNROOF MOTOR/SUN SHADE COMPLETED
      REINSTALLING MY OLD CRUISE CONTROL STALK
      HEADLINER COMPLETED
      HEADLINER IN
      INTERIOR INSTALL
      THROTTLE BODY CLEANING
      DEEP CLEANING FURTHER
      DEEP CLEANING FURTHER 2 (DRIVERS SIDE DOORS)
      RAIN TRAY REFRESH
      SUSPENSION REFRESH/COIL INSTALL
      EXHAUST INSTALL New!

      SOME OTHER COOL BUILDS
      WOLFSBURGNATE BUILD: THREAD
      GEORGEBOOLE NO BUILD
      03-UNI-B BUILD: THREAD
      PASSATTIMMY BUILD: THREAD
      GRAEME86 OEM+ Website: Graeme's Webspace
      JETTAUPANDGO BUILD THREAD
      EINKAUFSWAGEN BUILD: THREAD
      REVOKED DUB BUILD: THREAD
      RAND0MHER0 BUILD: THREAD
      FEOLA86 BUILD: THREAD



      My previous GL Golf build, LINK TO PREVIOUS THREAD

      My old vehicles.



      Here is the Turd bucket.



      These are not in order if they are not completed, just ramblings of things I would like to do, and where I’m at with them. See anything you think I’m missing? Let me know!


      • Polo Euroswitch - COMPLETED
      • 04+ Center Console - COMPLETED
      • Cut shifter - COMPLETED
      • Big knob install - COMPLETED
      • Refresh interior plastics - COMPLETED
      • Replace Center vent - COMPLETED
      • Pillar reupholster - COMPLETED
      • Obtain engine cover - COMPLETED
      • Headliner reupholster - COMPLETED
      • Parcel shelf reupholster - COMPLETED
      • MFA cluster - COMPLETED
      • Deep cleaning all things - COMPLETED
      • Front Wheel spacers - COMPLETED
      • Front end refresh kit - COMPLETED
      • Coilover suspension - COMPLETED
      • Frame Notch - COMPLETED
      • Sway Bar Delete - COMPLETED
      • Replace Rear View Mirror - COMPLETED
      • SRS Catback Exhaust - COMPLETED
      • Replace Intake Shift Rod Bushings & Actuator - COMPLETED
      • Replace Fuel Tank - COMPLETED
      • Replace Rear Beam Bushings - COMPLETED
      • Install Sony XAV-A100 - IN TRANSIT
      • Install Set of 4 SPS-610c Speakers - IN TRANSIT
      • Replace Both Inner and Outer Tie Rods/Ends - IN TRANSIT
      • Replace Headlights - IN TRANSIT
      • Replace Exhaust Hanger Bushings - IN TRANSIT



      -Charles
      Last edited by Charles Devine; 04-12-2017 at 04:09 PM.
      Youtube Dahui9 Eonon GA5153 Review Here

      24V MK4 JETTA

    2. Member Charles Devine's Avatar
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      03 Jetta GLI 24V Manual | 09 GTI 2.0T TSI DSG
      05-01-2014 11:14 AM #2
      Now on to the boring start! When I picked the car up, it was filthy and had some bad cosmetic and not so bad mechanical issues. Check engine light for CAT & O2, with a quick VCDS to clear codes and it didn't come back, broken center vents and the above radio cup holder was gummed up with what looked like the usual soda explosion. I noticed the soft touch peeling also but for the price of $3500 I couldn't pass up the offer when everything else was going for $5-6k.

      Here is where she sat when I got home (2013 TDI behind her)



      First things first, I removed the horrible sunroof shield, and front Europlate and trashed it as it was drilled into Then I come to find out the person who put it on not only drilled the plate but the bumper itself with self tapping screws (not just the rub strip with the factory front plate holes)



      I installed my First and only MOD for a bit, Forge BIG KNOB and cut the shifter down. (none of the install)



      I started to disassemble and in about 20 minutes had the car in pieces. My pool table



      The radio wouldn't come out so I had to get creative by pulling the cage only to remember from before this wouldn't work so it came down to the credit card method.



      and finally ended up here



      Picture of the center mount with broken vents removed.



      After removing this I went through my spare parts to see if I could put something together instead of having to buy used parts, ultimately I had to buy vents online just to add on to all the stuff you see, someone had an iPhone adapter for the Monsoon system in there that was the biggest POS which had brought on most of this work. I literally ripped that crap out and just shook my head at how the radio was just jammed back into the cage with no care for the harness and it had all these pinched wires (not pictured)



      That concluded the first night.

      The second day I had the car, the Wife and Son went out of town for 4 days so I started getting to work on the car. The car was so filthy I had to remove all the seats and clean the car completely out. (other than my tools all over the place you can see how bad it was.)

      Before



      I couldn't get the ground out hairs as I didn't have the "tools" but that should be resolved soon.

      After



      With the seats removed and the interior almost completely out I wiped down the rest of the car and cleaned everything including the motor (Gunk citrus engine cleaner) its hard to tell but a ton of gunk was removed, I forgot to get a dry before picture, sorry.

      Before



      After first treatment



      I still have a couple more treatments to go but I noticed after the valve cover gasket was leaking so I didn't do any more water in the engine bay.

      I then decided well since my seats are out, I should probably try to get them back to as decent shape as they can be on my limited maintenance only budget.



      After all was said and done they turned out.... okay.



      Then I decided since all that is out I might as well try to fix the interior pieces with the soft touch, taking things apart I discovered just how nasty things were, so I broke out the citrus cleaner again and went to town taking little pieces apart and even window switches off the panel itself to remove the hard stuff

      Before



      After



      Received a new center vent but had some peeling issues so I decided to take that completely apart and clean it also (careful to remove the LED's)

      Clean is left dirty right (hard to tell but they were filthy)





      Then for the soft touch lots of oven cleaner, scrubbing, and finally just sanding components, I came out with something decent after spraying the parts with about 5-6 coast for Krylon Flat black. There were some imperfections, but until I can get the parts in a paint booth this will do...

      Console


      Center vents


      Entire front center console, things sanded and painted (cup holder, vent shroud, center console soft touch area, ash tray) basically anything that had soft touch in the car has been completed



      That's it for the pictures right now, I have some more on my phone that I couldn't upload of the door handles that were redone as well.

      Thanks for looking!

      -Charles
      Last edited by Charles Devine; 09-22-2014 at 09:13 AM. Reason: Engine cover acquired
      Youtube Dahui9 Eonon GA5153 Review Here

      24V MK4 JETTA

    3. Member Charles Devine's Avatar
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      03 Jetta GLI 24V Manual | 09 GTI 2.0T TSI DSG
      05-04-2014 06:24 PM #3
      Today I managed to get 2 things done, my 04+ center console but still need a new armrest..




      And rednecked (swiss cheesed) the stock airbox for a little more sound, throttle response for now.



      That was it for today, soon to come its time to redo the headliner

      -Charles
      Last edited by Charles Devine; 06-12-2014 at 08:36 AM.
      Youtube Dahui9 Eonon GA5153 Review Here

      24V MK4 JETTA

    4. Member Pasquallies's Avatar
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      2014 Hyundai Veloster Turbo --05.5 Audi A4 3.2L (sold) --01 JTI VR6 (sold) --97 GTI 2.0L (sold)
      05-04-2014 09:56 PM #4
      Nice start.

      I'll watch
      DrtyEuro l FLOSSFilthy l VRalliance #1
      For VRalliance stickers and tee shirts PM "sixxxball"

    5. Member
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      05-04-2014 10:04 PM #5
      Nice quality work

    6. 05-04-2014 10:21 PM #6
      Sub'd

    7. Member NOpassattimmy's Avatar
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      04 1.8T GTI-R.I.P. 05 1.8T JTI-Money Pit
      05-05-2014 02:58 AM #7
      Not bad

      I have sunvisors and rear headliner lights if you need them. PM me if you wanna work something out
      Quote Originally Posted by jobothehobo View Post
      passattimmy.... you're a boss
      Plug and play harness for lit Jetta vents|Insta: @_timdonahue|My Rare Parts Hoard

    8. Member Charles Devine's Avatar
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      03 Jetta GLI 24V Manual | 09 GTI 2.0T TSI DSG
      05-05-2014 12:13 PM #8
      Quote Originally Posted by passattimmy View Post
      Not bad

      I have sunvisors and rear headliner lights if you need them. PM me if you wanna work something out
      Thank you guys for the comments, from here on its going to be a very slow pace but it will come together. Other priorities as I have mentioned.

      Also PM sent passattimmy.

      While I'm commenting for those reading, I know its not visible but I have what looks like very rough spots on the leather, but I think it can be recovered, In the image pictured below right above the hole is about how it looks, I've looked around the interior forums but most of the tricks I've looked at aren't really working. I want to know what really works? I'm thinking of resorting to a leather shoe restore?



      -Charles
      Last edited by Charles Devine; 06-12-2014 at 08:37 AM.
      Youtube Dahui9 Eonon GA5153 Review Here

      24V MK4 JETTA

    9. Member boradie sucht's Avatar
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      mk4/mk5
      05-05-2014 12:34 PM #9
      keep up the good work!
      jettaaddiction #ripvwvortex

    10. Member Charles Devine's Avatar
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      03 Jetta GLI 24V Manual | 09 GTI 2.0T TSI DSG
      05-13-2014 03:35 PM #10
      Well to update today, nothing has been done on the car for the past week or so other than cleaning. The main reason being the previous owner I guess didn't know the batter needed water. All the water out of one of the cells was gone, I tried to save the battery but it is toast. I currently have a spare battery out of my Pop's Dakota in there just to drive the car until I am provided my car allowance for this paycheck.

      I did however start the process for the headliner, I'm awaiting a swatch of Faux/Suede material that stretches to see if its worth buying. The next update will probably be when this is completed.

      Oh I'm on the look out for your any black upper interior parts you may want to throw my way to speed this process along for the fun stuff. I'd like to know everyone's thoughts on spraying them with the same paint I used to remedy myself of the soft touch junk?

      For giggles my old headliner



      -Charles
      Last edited by Charles Devine; 09-16-2014 at 08:06 PM.
      Youtube Dahui9 Eonon GA5153 Review Here

      24V MK4 JETTA

    11. Member TheSiwwyWabbit's Avatar
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      2002.5 VR6
      05-13-2014 03:48 PM #11
      holy moly the PO was a slob. nice to see it in good hands.

    12. Member Charles Devine's Avatar
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      03 Jetta GLI 24V Manual | 09 GTI 2.0T TSI DSG
      05-13-2014 08:41 PM #12
      Quote Originally Posted by TheSiwwyWabbit View Post
      holy moly the PO was a slob. nice to see it in good hands.
      No comments there but the pillars are out, sorry for the dirty floor, those pillars are simply gross



      The reason why we are doing this







      I know everyone is like wow what a lame thread, but my little man is my main priority.



      Until the headliner replacement!

      -Charles
      Youtube Dahui9 Eonon GA5153 Review Here

      24V MK4 JETTA

    13. Member im_lower's Avatar
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      2013 Mustang GT 5.0, 11 Tacoma TRD, 1981 Benz
      05-13-2014 08:55 PM #13
      Your attention to detail is phenomenal. Keep it up dude.
      How old would you be, if you didn't know how old you were?

      Alaskan Green build thread.

    14. Member Charles Devine's Avatar
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      03 Jetta GLI 24V Manual | 09 GTI 2.0T TSI DSG
      05-13-2014 09:00 PM #14
      Quote Originally Posted by im_lower View Post
      Your attention to detail is phenomenal. Keep it up dude.
      Thanks this is basically my dream car so I want to make sure its done correctly.

      -Charles
      Youtube Dahui9 Eonon GA5153 Review Here

      24V MK4 JETTA

    15. Member
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      05-13-2014 09:10 PM #15
      Good start

    16. Member
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      05-13-2014 10:48 PM #16
      I never thought about just painting the soft touch pieces. I have some flat black Krylon Fusion paint left over from another completely different mod. I might have to try that. Did you just sand off all of the soft touch crap and then paint it?

      Also, looking good.

    17. Member Charles Devine's Avatar
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      03 Jetta GLI 24V Manual | 09 GTI 2.0T TSI DSG
      05-14-2014 10:08 AM #17
      Quote Originally Posted by pez910 View Post
      I never thought about just painting the soft touch pieces. I have some flat black Krylon Fusion paint left over from another completely different mod. I might have to try that. Did you just sand off all of the soft touch crap and then paint it?

      Also, looking good.
      Well there were quite a few steps that didn't work but what I wound up doing was leting them set in water over night with dawn dish soap. Then using oven cleaner to remove all the soft touch that was rotted and falling off by scrubbing with a scotch brite pad (like on the back of a sponge). I then sanded with a 240 grit not vigorously but enough to see scratches to try remove leftover soft touch (you may get discoloration in some areas more than others). To clean I used alcohol, then with light coats i sprayed about 5-6 allowing 15 minutes to dry in between sprays.

      Just an FYI for those curious on long term left over soft touch, I figure, 12 years sitting is long enough to rot fully away, if it doesn't want to come off it will stay and should bond with the paint. There is not any noticeable discoloration in the transition areas.

      Pro Tips from my experience. DO NOT USE ACETONE OR MINERAL SPIRITS, it breaks down the plastic and leaves it sort of pitted. Yes it does remove the soft touch quite fast, but you will run through so many napkins trying to rub away areas not to mention ruin your smooth plastics. Also remove any gouged areas in the soft touch that remain, if not it will show through the paint. I have to redo a couple of pieces because of areas I thought the paint would fill in.

      -Charles
      Last edited by Charles Devine; 05-14-2014 at 10:15 AM.
      Youtube Dahui9 Eonon GA5153 Review Here

      24V MK4 JETTA

    18. Member connorhelm's Avatar
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      2000 jetta gls vr6
      05-14-2014 10:22 AM #18
      Looks good Charles! Wish I would have waited for a 24v to come around


      Sent from my iPhone using Tapatalk
      2000 jetta gls vr6

    19. Member
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      03 jetta 1.8t, 03 dakota RT
      05-14-2014 11:30 AM #19
      Just curious but you said this is a GLI? anyone else notice that there are none of the GLI parts? I.e. Wheel, badges, trim, gauges, 6 speed? Was there a GLI without this stuff?


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    20. Member Charles Devine's Avatar
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      03 Jetta GLI 24V Manual | 09 GTI 2.0T TSI DSG
      05-14-2014 11:53 AM #20
      Quote Originally Posted by Spunker View Post
      Just curious but you said this is a GLI? anyone else notice that there are none of the GLI parts? I.e. Wheel, badges, trim, gauges, 6 speed? Was there a GLI without this stuff?


      Sent from my iPhone using Tapatalk
      US differences for this model are as follows but not limited to these things.

      02-04 GLI

      24V VR6 units with black lower interior grey upper, no accents or body kit, 6 spd.

      04.5+ till MKV

      Change to the anniversary edition that was an all black interior with special seats/accents, 1.8t engine with 6 spd, and body kit.
      Last edited by Charles Devine; 05-14-2014 at 01:29 PM. Reason: clarification
      Youtube Dahui9 Eonon GA5153 Review Here

      24V MK4 JETTA

    21. Member
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      03 jetta 1.8t, 03 dakota RT
      05-14-2014 11:57 AM #21
      Learn something new every day


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    22. Member
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      03 GTI VR6
      05-14-2014 01:10 PM #22
      Quote Originally Posted by tiggo View Post
      Well there were quite a few steps that didn't work but what I wound up doing was leting them set in water over night with dawn dish soap. Then using oven cleaner to remove all the soft touch that was rotted and falling off by scrubbing with a scotch brite pad (like on the back of a sponge). I then sanded with a 240 grit not vigorously but enough to see scratches to try remove leftover soft touch (you may get discoloration in some areas more than others). To clean I used alcohol, then with light coats i sprayed about 5-6 allowing 15 minutes to dry in between sprays.

      Just an FYI for those curious on long term left over soft touch, I figure, 12 years sitting is long enough to rot fully away, if it doesn't want to come off it will stay and should bond with the paint. There is not any noticeable discoloration in the transition areas.

      Pro Tips from my experience. DO NOT USE ACETONE OR MINERAL SPIRITS, it breaks down the plastic and leaves it sort of pitted. Yes it does remove the soft touch quite fast, but you will run through so many napkins trying to rub away areas not to mention ruin your smooth plastics. Also remove any gouged areas in the soft touch that remain, if not it will show through the paint. I have to redo a couple of pieces because of areas I thought the paint would fill in.

      -Charles
      Awesome! Thanks for the detailed reply! I'm going to have to give this a shot the next time I get a couple days off in a row.

    23. Member Countryboy07's Avatar
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      2002 VW Jetta TDI
      05-14-2014 05:03 PM #23
      Great Start!
      2002 Jetta TDi - Some things done... ~Constantly under construction~

    24. Member Charles Devine's Avatar
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      03 Jetta GLI 24V Manual | 09 GTI 2.0T TSI DSG
      05-19-2014 09:05 AM #24
      Okay, I know I said I would have the headliner done this time, but this is my thread for future viewing pleasure.

      Very small maintenance update, with more problems found.

      Found out why my front left tire was constantly leaking, I haven't driven the car much or taken the tires off to check until now, but come to find out the it looks like the previous owner I don't think to ever rotated or checked the tires from the looks of it... Inner tire was showing threads, The car had been run on low pressure for so long it wore down the outer edges of the front tires. So I had some used tires from back when I had my other MKIV that are a little "BIG" but they will work until we start really getting into the nitty gritty of the build later on.

      Bubbly tire! (Don't mind the AU sticker, Dads truck, sisters school = Stickers all over truck)



      So after doing that I decided to check the entire suspension and the underside of the car that I couldn't really see without a jack when buying the car. I wound up finding my mysterious acceleration clunk... turns out the control arm bushings are shot, so we will be doing a complete rebuild of the front end. Eventually I would like to get these URST control arms but for now "patience young grasshoppa".

      Broken rear bushing passenger control arm (same on the drivers side)



      Finally I did manage to be productive on this build and removed my headliner which has a ton of crap in it so now I have to vacuum and detail my car again.




      I had to restore my phone this weekend and I'm not to sure if I erased the rest of the photos but I will find them and post them. I've been scraping more and more of the foam backing off when letting the dogs out to clean the headliner up for the suede that will be going on.

      To come in the next update, probably will have to prep and spray my grey plastic pieces for now, new battery, and time permitted headliner fully finished. I've been looking a lot on how to install black suede on these headliners, its going to be hell either way but I have a friend that does it for a living that is going to help. I do not want any creases if I have them I'll redo it until is correct! syfabrics.com micro stretch suede is cheap and thin so I will not being using that...

      Thoughts on this
      - delete grab handles?
      - foam backed suede or not for ease of install?
      - shark fin antenna while the headliner is off?
      - suede sunvisors? to much?
      - best find for suede that doesn't fade?

      -Charles
      Last edited by Charles Devine; 09-16-2014 at 08:06 PM.
      Youtube Dahui9 Eonon GA5153 Review Here

      24V MK4 JETTA

    25. Member joeydee's Avatar
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      2004.5 gli <-sold Mk6 gti
      05-19-2014 09:16 AM #25
      good luck

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