VW Beetle Forum banner
1 - 20 of 24 Posts

·
Registered
Joined
·
147 Posts
Discussion Starter · #1 · (Edited)
All stock, 159,000 miles. Bought used, one owner, timing belt and fuel pump issue. Had head rebuilt. Turbo, clutch, replaced. Very nice car now, almost like new. Nice leather interior in very good shape as well. Gave $1200 for the car. $3300 in repairs. All repairs being done by our local trusted TDI mechanic. Way cheaper and better than a new car. The economy of these TDI's is amazing as well. Hope I get a good long run out of it!



















 

·
Super Moderator
Joined
·
14,833 Posts
Looks like it's in good condition! Thank you for taking this TDI into your family!! :clap:
 

·
Super Moderator
Joined
·
5,367 Posts
I love that color it looks great! As Deb said looks to be in good condition, congrats :)
 

·
Registered
Joined
·
147 Posts
Discussion Starter · #4 ·
Took it out for its first ride last weekend after the head and stuff was rebuilt. Found a high centered road and ground a hole in the brand new oil pan. Back to the mechanic for a new oil pan and DieselGeeks Panzer plate with full side armor. $700

Sun baked plastic started breaking off in the interior and rubber soft touch parts sticky. Ordered new door panels($700), center dash panel($168), glove box($230) and a few trim pieces($15). Plus DieselGeeks door handle reinforcement steel($30). I had already ordered and had painted a whole new front grill set and fog lights. They are ready and all put together and ready to install. When all this comes in it will be installed and should hold me for a while. Car is starting to look like new!
 

·
Registered
Joined
·
147 Posts
Discussion Starter · #5 ·
Total repairs and upgrades so far.

First bill for repairs on 9/2/2015:

Make/model 03 Beetle
mile 157,450
$1200

Labor:
Description: Charge:
Install injection pump seal kit $ 312.11
Install timing belt kit $ 385.00
R&I cylinderhead ([email protected]$90/hr) $ 540.00
Install lower radiator hose and repair expansion tank hose $ 45.00
Install inner drive axle boot, right and left (1.5hr/side) $ 270.00
Install fan set $ 90.00
Install glow plug harness $ 90.00
install oil pan $ 90.00

Total Labor: $ 1,822.11

Outside services:
Brooks Elliot Machine Shop head repair service exchange $ 280.00
Brooks Elliot Machine shop intake cleaning service exchange $ 50.00
Total: $ 330.00

Parts:
Description: Unit Price: Total Price:
1 Bosch IP seal kit $ 21.00 $ 21.00
1 fuel return line set $ 5.00 $ 5.00
1 dieselgeek.com ALH timing belt kit with $ 340.00 $ 340.00
timing belt, tensioner, water pump, 3 rollers
vacuum pump seal and serpentine belt
1 cylinder head gasket, 2 hole $ 23.40 $ 23.40
10 cylinder head bolt $ 1.26 $ 12.60
1 intake manifold gasket $ 2.00 $ 2.00
1 exhaust manifold gasket $ 9.95 $ 9.95
1 down pipe gasket $ 3.00 $ 3.00
1 EGR to intake o-ring, viton $ 5.00 $ 5.00
3 EGR pipe gasket, metal $ 3.95 $ 11.85
1 EGR pipe gasket, paper $ 3.80 $ 3.80
4 injector crush washer $ 0.90 $ 3.60
1 turbo oil return line gasket $ 4.00 $ 4.00
1 camshaft $ 100.05 $ 100.05
8 cam follower, INA $ 9.42 $ 75.36
1 camshaft oil seal, PTFE $ 10.00 $ 10.00
2 intake valve $ 13.00 $ 26.00
1 water outlet flange o-ring $ 5.00 $ 5.00
1 lower radiator hose $ 36.18 $ 36.18
1 hose repair union, repair hose and clamps $ 11.00 $ 11.00
2 drive axle boot, inner $ 20.00 $ 40.00
4.5 Fuchs Titan Supersyn 5w40 motor oil, liter $ 6.66 $ 29.97
1 oil filter $ 8.00 $ 8.00
1 glow plug harness $ 102.00 $ 102.00
1 cooling fan, left $ 66.37 $ 66.37
1 cooling fan, right $ 68.27 $ 68.27
1 oil pan $ 88.00 $ 88.00
5 G12 coolant, mixed 50:50 distilled H2O, liter $ 3.00 $ 15.00
1 coolant expansion tank $ 18.24 $ 18.24

subtotal $ 1,144.64
Tax: $ 94.43
Part Total: $ 1,239.07

Invoice Total: $ 3,391.18


Second bill for oil pan incidinet on 9/9/2015:

Make/model 03 Beetle
mile 157, 676

Labor:
Description: Charge:
Install oil pan $ 90.00
Install dieselgeek panzer plate w/ FMJ $ 60.00

Total Labor: $ 150.00

Parts:
Description: Unit Price: Total Price:
1 dieselgeek.com Panzer Plate kit $ 275.00 $ 275.00
1 side dkirt FMJ set $ 99.00 $ 99.00
1 oil pan $ 88.00 $ 88.00
4 Fuchs Titan Supersyn 5w40 motor oil, liter $ 6.66 $ 26.64

subtotal $ 488.64
Tax: $ 40.31
Part Total: $ 528.95

Invoice Total: $ 678.95

Car wasn't running so I bought a clutch set just in case:

$33.93 Volkswagen 02J 141 719 C, Clutch Release Arm
$34.33 Victor Reinz 67750 Rear Main Seal
$187.57 LuK 17-050 Clutch Set
$22.50 Axle Shaft Seals (2)
$12.00 CV Joint Bolt (12)
$1.75 Retaining Spring for Clutch Release Lever Pivot
$85.90 Clutch Slave Cylinder (A4)


$9.30 Audi Vw Mercedes Double Din Radio Removal Key Tool (2 Pair)
$72.97 New fog light set Amazon by AutoHalo.
$58 Dieselgeek Beetlebrace door handle reinforcement
$200 Maaco painting of front grill parts
$50 Bentley Beetle Manual

VW OEM Parts - | ExpressOEMParts.com

Part Number Part Name Price Quantity Total
1C0-805-903-G-GRU LOWER PANEL $105.21 1 $105.21
1C0-807-681-E-01C LOWER GRILLE $39.71 1 $39.71
1C0-807-341-A-GRU COUPLING $57.12 1 $57.12

Subtotal: $202.04
Shipping (UPS - Ground): $60.24
Handling: $2.75
Total: $265.03

Part Number Part Name Price Qty Total
1C0-868-107-B-FYZ DOOR TRIM PANEL, LEFT $350.03 1 $350.03
1C0-868-108-B-FYZ DOOR TRIM PANEL, RIGHT $350.03 1 $350.03
1C1-857-628-B-62J GRIP HANDLE CAP, RIGHT $4.55 1 $4.55
1C1-857-627-C-62J GRIP HANDLE CAP, LEFT $4.55 1 $4.55
1C0-858-069-AA-XNX CENTER BEZEL $165.12 1 $165.12
1C1-880-882-E-3SG GLOVE BOX DOOR $229.72 1 $229.72

Subtotal: $1,104.00
Shipping: $80.61
Handling: $2.75
Total: $1,187.36



Total so far: $7693.27
 

·
Registered
Joined
·
147 Posts
Discussion Starter · #6 ·
Completed replacing new drivers door panel. It took a while to transfer everything over from the old door. What I hadn't counted on was the top trim piece is kind of plastic welded on like the arm rest leather piece is. I thought there would be some other fastening to remove it and replace it on the new panel. NOT! I had to order 2 new top trim panels at $150 each. I had a choice of primer or black. I ordered black. If they look okay I will leave them that way. If not I will have them painted to match again like the originals. I am going to try and get the center dash bezel and glove box door done tomorrow morning while it is cool out. My ProClip mount for my phone arrived and I will be installing it as well.
 

·
Registered
Joined
·
147 Posts
Discussion Starter · #7 ·
Completed and reinstalled door panels. The passenger side had to have some cutting done to the foam on the new door panels. It was too big and wouldn't let the panel fit up against the door.





New suspension arrived with new springs/struts/shocks and all other associated parts. $650

2" lift kit $300 ($100 deposit refundable)

New OEM carpeted floor mats $88

New shift boot $28

New spare key and remote $68
 

·
Registered
Joined
·
15,840 Posts
Wow, you have spent allot; to get the car back in tip top shape, you have gone through the car thoroughly and added some nice upgrades, like the panzer plate and new door panels. It sounds like your New Beetle; should be ready, for many more years of driving fun! Did you anticipate; spending this much money on a older car vs. getting a newer model with less miles, better condition? I'm just curios; about what your perspective was; going into the purchase of your New Beetle. One thing is for sure; the fact that it is a TDI, makes the idea of the engine lasting longer then a gas one, a reality and the amount of miles people put on these engines, is pretty amazing. I have found with most older used cars; you cannot anticipate; all the issues, it has until you really drive the car for awhile and start tearing into everything, working out what needs to be repaired and replaced. Your car looks great; I like the color and the door panels set the car off nicely. :) After all this work; how long do you plan on keeping and using the car?
 

·
Registered
Joined
·
147 Posts
Discussion Starter · #9 · (Edited)
Wow, you have spent allot; to get the car back in tip top shape, you have gone through the car thoroughly and added some nice upgrades, like the panzer plate and new door panels. It sounds like your New Beetle; should be ready, for many more years of driving fun! Did you anticipate; spending this much money on a older car vs. getting a newer model with less miles, better condition? I'm just curios; about what your perspective was; going into the purchase of your New Beetle. One thing is for sure; the fact that it is a TDI, makes the idea of the engine lasting longer then a gas one, a reality and the amount of miles people put on these engines, is pretty amazing. I have found with most older used cars; you cannot anticipate; all the issues, it has until you really drive the car for awhile and start tearing into everything, working out what needs to be repaired and replaced. You car looks great; I like the color and the door panels set the car off nice. :) After all this work; how long do you plan on keeping and using the car?
I don't plan on getting rid of it as long as I can maintain it. I sold my 2013 Passat due to potential layoff and didn't want any debt. With all of the complicated issues with all the newer models I went with the tried and true alh model car. I have been driving their diesels since 2005. This is my second Beetle and I like them. Long production time so lots of spare parts around. These are much cheaper and simpler to work/maintain then any of the newer models. I have gone to the expense of making it like new as that is what I wanted instead of a new car and it is much cheaper. It has cost more to get in shape as it was initially advertised as having only a IP (injection fuel pump) leak. Turned out to have a bad timing belt install as well with an improperly set tensioner. This took out the head, valves and cam which needed work/replacing to the tune of $3500 or so. This was a one owner car and initially looked very nice interior wise. But all of the plastic is very brittle and the door handles broke almost immediately as well as some other stuff. I decided to buy new door cards as the nicer used ones out there were $400 or more anyway and they were used. For a few hundred more I got brand new ones. I was impressed with the front grill being intact and nice when I bought it, but tore it up on the tow dolly getting it to my trusted mechanic. So replaced and painted that. I forgot how low these cars are and ripped out the brand new oil pan the first day I got it back from my mechanic. So new oil pan and full Panzer plate with side armour. I am totally refreshing the springs and shock/struts etc plus a 2" lift to get it off the ground some to stop grinding the bottom of the car. It should look similar to this car only without the Baja stuff and I used normal stock Beetle springs instead of higher ones.

http://newbeetle.org/forums/photos-new-beetles/58277-blue-02-gls-baja-lifted-off-road.html

I ordered a new radio yesterday to try and get BT back for phone use like my Passat had. Kenwood KDC-BT762HD and maybe some Polk Audio DB651 6.5"/6.75" 2-Way Marine Certified db Series Car Speakers with Liquid Cooled Silk Tweeters if the stock speakers don't sound well with it. I will be swapping the center dash bezel and glove box door this afternoon. Some new carpet mats coming in with a new shifter boot as well. That should take care of the inside. I need 2 new emblems for the hood and hatch and a couple of small paint scratches fixed. I have way more into it than it is actually worth to anyone else but me. Still way less than the $32k I paid for my Passat though! Thanks for looking and commenting! Here are a few current pics:











I have new pieces for the center dash bezel to fix AC vents and grab bar trim pieces on either side, as well as new glove box door.






My trusted mechanics handiwork.
 

·
Registered
Joined
·
147 Posts
Discussion Starter · #10 ·
Added new carpeted OEM floor mats and a new shifter boot. Reprogrammed new key for remote functions. I also got the whole new painted grill installed with new fog lights.
 

·
Registered
Joined
·
15,840 Posts
With all the new parts; the interior and car, look amazing! The interior and many parts; just don't last on these cars. Good job and there is definitely; something, to be said to have a car fully paid off! :) Each picture; the new parts, make the car look, better and better! :goodjob: Soon, many of these parts will be NLA from VW; so, good you got them now, while still available! :p
 

·
Registered
Joined
·
147 Posts
Discussion Starter · #12 · (Edited)
I got the glove box opened and found the owners manual inside along with all the original sales paperwork including the Monroney label. Kind of a nice surprise. The New Beetles had a pretty long run so I think more parts are available still had they not had a decade or so run. But soon they will start drying up so I am glad to have new.

The new suspension refresh has all arrived now and the 2" lift kit from Metalnerd. Just waiting for the new fuel injectors with the DLC 520 nozzles to arrive. I also ordered a Flashzilla device and a Malone tune stage 2. That should take it from 90 hp to 137bhp/257lb-ft. That should wake it up a bit and still maintain fuel economy for the most part.

new suspension kit from IDParts.

http://www.idparts.com/

1 x Spring & Shock Complete Suspension Set (A4) (a4_tc_springs_set) = $515.60
Rear Bump Stops
Installation Bolt Kit
Front Bump Stops
Rear Shock Mounts
Model New Beetle
Shock Option Bilstein TC Sport
Front Strut Mounts FREE
2 x Front Spring Top Perch (A3)(B4)(A4) (springtopa4) = $23.98
1 x Rear Shock Boot / Dust Covers Pair (A4) (a4_rshock_cover_pair) = $9.95
2 x Strut Mount Top Nut (A4) (struttopnuta4) = $16.40
2 x Rear Lower Spring Seat (A4) (a4rearspringseat) = $16.40
1 x Front Strut Boot/Covers Pair (A3)(A4)(B4) (a4_strut_boot) = $18.95
2 x Audi TT Control Arm Rear Bushing (A4)(A3)(B4) (ttcabusha4.jpg) = $37.90
------------------------------------------------------
Sub-Total: $639.18
IDEAL IDeal Economy (5-7 Days) (54 lbs.): $4.95
Total: $644.13

Then 2" lift kit from Metalnerd. $300 (Includes a $100 refundable deposit)

http://www.metalnerd.com/cat09.htm
 

·
Registered
Joined
·
6 Posts
I don't plan on getting rid of it as long as I can maintain it. I sold my 2013 Passat due to potential layoff and didn't want any debt. With all of the complicated issues with all the newer models I went with the tried and true alh model car.

These are much cheaper and simpler to work/maintain then any of the newer models. I have gone to the expense of making it like new as that is what I wanted instead of a new car and it is much cheaper.

I have way more into it than it is actually worth to anyone else but me. Still way less than the $32k I paid for my Passat though! Thanks for looking and commenting! Here are a few current pics:
This is the same kind of story with my current Golf TDI and what the future story of my Beetle TDI will be.

I don't have any potential lay-off issues, but I just don't want a newer car. I don't want all the gadgets, and I don't want the payments and debt that go with it either. I can afford a new car no problem...and I even get paid mileage for my work, but I just don't want one.

Like your Beetle, I have way more money into my Golf than the car is worth to the general public (or a non-enthusiast). The Beetle will quickly be the same.

Your car looks great. I envy that dry rust free southern air. Our plastics don't rot here like yours do (from the sun) but our steel rots at record speeds. It's really unfortunate...for those of us that prefer the slightly older cars;).

Rem
 

·
Registered
Joined
·
147 Posts
Discussion Starter · #14 ·
Pics of some of the completions today.

New center dash bezel installed with working AC vents and non-scarred up rubber coating.



New glove box door and new grab bar end pieces.



New shifter boot and knob.



New Beetle carpeted floor mats.

 

·
Registered
Joined
·
15,840 Posts

·
Registered
Joined
·
9 Posts
Wow! Beautiful bug! You've managed to do in pretty much one fell swoop what I've been working on for over a year now. :p
 

·
Registered
Joined
·
147 Posts
Discussion Starter · #18 ·
Thanks! A lot of credit must go to the original owner for taking good care of it. Then to my trusted mechanic and his assistant for getting it running and mechanically in good shape. The cosmetic work has mostly been me. It is nearing completion now and I am enjoying driving it a lot. Just wish the crayon smell were gone too. Maybe one day I will pull the carpet and underlayment out and redo it as well. With the suspension and injectors going in soon and the addition of the Kenwood headunit, I don't see much more to do. Oh the ash tray/power point was missing in the back and I ordered one of those to replace the missing item.
 

·
Registered
Joined
·
147 Posts
Discussion Starter · #19 · (Edited)
Added new headlights today. Someone was parting out a Beetle that had new headlights in it. Perfectly clear lenses and in like new condition, $80. I am taking the old headlight units and converting them to Bi-Xenon HID. Ordered some Morimoto FX-R's and some MC-R (Mini Clubman replica) shrouds. To start mocking up the change. One of the members here and over at TDIclub had done this back in 2011/2012 but just disappeared without finishing completely. I will follow the posts there as much as possible in doing this.

http://newbeetle.org/forums/styling-modifications/51893-new-beetle-bi-xenon-retrofit.html

http://newbeetle.org/forums/technical-modifications/51818-mini-h1-bixenon-retrofit.html

http://forums.tdiclub.com/showthread.php?t=326422

I also need to go back into the passengers side door. I either forgot to connect the door latch cable or it broke something. I was missing an ashtray for the rear of the center console. I found out it could be a power point instead. Ordered it from ECS Tuning for around $75 with shipping. It came in and I went out to install it and found the panel in the back of the console was broken for the attachment/pivot points as well. Ordered another one of those from ECS for around $95 shipping included as well.
 
1 - 20 of 24 Posts
Top