Central Florida

TDI Club
Dec 2010 Newsletter of the Central Florida TDI Club Chris Mendola, Editor doctordiesel@cox.net
VW-TDI : Very Willing To Deliver Information/Ideas

Central Florida TDI

Group celebrates with
fantastic lasagna dinner
& terrific discussions,
tech sessions, fellowship and info sharing
The October 16th, 2010 Get-Together of the Central Florida TDI Club was unique in several ways.
First, this was our first GTG to be held on a day
other than a Sunday. Folks have been requesting
that we shift from Sunday to Saturday and our
movement was slow, only due to concern that
certain inaugural members couldnt attend other
than on Sundays. Then we were unsure if folks
who occasionally or never have attended would
even come out on a Saturday.

The Best Yet !

That certainly has to describe the October GTG of the Central Florida
TDI club. As mentioned in the previous column at the left, our attendance
was the highest to date, some 27 folks turning out for our luncheon and
get-together. Many topics were covered, camaraderie was super high,
cars were parked all over, and technical info and advice was shared and
appreciated. There were also some unusual door prizes, so everyone
seemed to have a good time and enjoy themselves.
Read on for some specifics that occurred

Discussions and hot topics

One of the parts of our GTG that I like the most is the discussions that
come up while were eating. This often takes the form of a topic for
open commentary, such as common problems folks are having with
their cars, or what new facts are being rumored for new VW models.
The floor is open to whoever has (authoritative) knowledge to share,
be it technical, sales-related, warranty, recalls, whatever.

Second, this GTG celebrated our highest attendance to date 27 participants. We almost had to
worry about having enough space for everyone to
have a seat and enjoy the luncheon. Though this
number is just a smidge above our usual Sunday
attendance, were going to try our next GTG on a
Saturday also.

For several years I held a subscription to Diesel Car magazine (later

changed to What Diesel magazine) from the United Kingdom. They
publish exclusively for diesel & alternative power readers. Also having
toured the UK on three occasions, I have rented foreign cars with the
last being a diesel-powered Citreon (mini-)mini-van. The difference
between my VW and the Citreon was noticeable with each having its
Third, the luncheon was superb! Our hostess, Sal- own advantages. The point of this comment is that diesel cars sold in
American are usually available in Europe before their arrival on this
ly Mendola, out did herself again with a fantastic,
homemade lasagna dinner featuring Italian bread, side of the Pond; what shows up in Europe sometimes makes its way
salad and beverages. Dessert was chocolate-chip Stateside a few years later.
cookies.

Fourth, our next GTG is set for a Saturday, March

26th, 2011 in Ocala. You must RSVP by Tuesday,
March 22nd. Cost is now $6 per person.
Correspondence is handled by (Mr.) Chris
Mendola via email: doctordiesel@cox.net or via
phone at 352-572-8421 or 352-694-3705.

The discussion moved up a notch, in my opinion, as we got talking

about diesel models only seen overseas, primarily Europe, and which
ones might eventually come over to the USofA. One of our members,
Tonino Tony Petrolo, was a longtime diesel mechanic in Europe and
still maintains contact with technicians over in the old country. (contd
page 2)
Please send any comments regarding this issue to Chris at:doctordiesel@cox.net.

Dear
Doctor
Diesel
Sometimes its the little
things that can make a
car repair easy or difficult,
successful or a nightmare.
In this column we share
ideas from members that
may or may not help you
with your next challenge.

Dear Dr. Diesel,

How do I get my headlight covers clear
again? There are so many products on the
market that PROMISE to work but Ive not
found a good one yet.
Ms. Unclear in Florida
Ive personally tried a number of procedures to
get my clear plastic headlight covers back to their
former, like-new, clear condition. Kit manufacturers
make all kinds of promises on their products
packaging but Ive never gotten the results that
were promised. I came closest when I buffed the
clear plastic cover with fine polishing compound.
Then, as if by a miracle, I re-discovered an old
product on my shop shelf that Id purchased about
20 years ago 3Ms Finesse-It II Finishing
Material, part #051131-05928. (This may be
an older #.)
Finesse-It II is a polishing liquid that is similar
to fine polishing compound yet different,
according to some auto paint sources. It is a lotion
in consistency and much wetter than buffing
compound. I applied it using an adjustable-speed
power polisher. (A simple, slow-revolution electricpowered buffer is not fast enough for this task. 3M
recommends 1500-2000 rpm with light to medium
pressure.)
Care must be taken to not run the polisher at too
high a speed and to also keep the polishing pad
moving around otherwise the friction of staying
in one spot too long will result in melting the
plastic. Using lighter pressure, if your buffer is of
the single-speed variety, may prevent burning
but be aware that the melting process happens
instantaneously, so constant attention is always
necessary.
If melting occurs, carefully buff-out the melt-spots.
Hand polishing may also work but my lenses were
too hazy so a power buffer was called for. They
look brand new! Hope this helps. Doc

Attendees at the GTG became interested in whether Chrysler would

bring diesels into the US now that Chrysler is economically attached
to Fiat (which bought into Chrysler when it was floundering last year).
Fiat has announced that itll bring the Fiat 500 sub-compact to the
US of A in 2011 or 2012. Similar in size to the Ford Fiesta and (BMW)
Mini, we wondered if Fiat would bring it with a diesel option. No one
had heard any substantiated rumors but Tony remarked that their
gasoline engine was certainly competitive with the diesels we have
now as it regards fuel economy.
Tony went on to explain Fiats Multijet diesel technology. Their
computer system varies the number of injections of diesel fuel into
the cylinder so as to reduce emissions, smooth the diesel knock,
and provide better efficiency. It was amazing to hear that Multijet
technology can provide up to 5 squirts into each cylinder per firing
thats right the computer can time FIVE squirts of diesel fuel
into each cylinder on each power stroke! Of course, as revolutions
increase this process occurs way too fast so the number of squirts are
reduced, but apparently are also not needed as much at higher RPM.
Also of interest was Fiats MultiAir gasoline engine technology
which dramatically reduces emissions while providing exceptional
performance AND mileage in European-emissions guise, achieving
low- to mid-40s in miles per gallon. And thats a gasoline-engined car!
One of the most frequent problems mentioned in What Diesel
magazine is the mistaken fueling of diesel cars with gasoline, which
often occurs due to lack of concentration at the pump or with folks
who drive both gasoline and diesel vehicles and forget what theyre
pumping fuel into.
Tony gave us some tech-talk on what to do if you accidentally put
gasoline in our tank instead of diesel fuel. I didnt take close notes, so
I dont want to mislead you, but Im sure hell share those insights at
future GTGs if you ask him.
Speaking of Tony, we also sang, For Hes A Jolly Good Fellow to him
in response to his wedding announcement. Tony is getting married in
January. Congratulations Tonino!
Luis Olivero, a frequent presenter at tech sessions, gave interesting
detaila on the repair of his newest TDI a 2003 (I think) Jetta wagon.
It apparently had seen better days and Luis got a good deal when
buying it, but his good deal came with some real detective work and
repair skills in order to get it running. Several months later he said it
was humming well until a road trip met with a major loss of power. He
thinks the turbo and/or its bearings went bad. But Luis is a real diesel
advocate and repair guru, so we expect the TDI wagon will be up n
running soon.

VW-OEM Parts Discounts

Cards with information about discounted parts prices from
two VW dealerships were also discussed. Both Gunther
VW in Coconut Creek (Ft Lauderdale) and VW of Ocala are
now extending a 20% discount to club members on most
parts. Some exceptions may be interior parts and some
others. If you have questions, give the dealer(s) a phone
call. A duplicate of the discount card distributed at the GTG
is printed on page 5 of this newsletter. Feel free to print it
out and use it, while also sharing additional copies with any
friends in need. Pete Raissis is the contact at Gunther VW
and David Farnham is the parts contact at VW of Ocala.
Does all this sound like interesting stuff to you? Then show
up for our next TDI-GTG, Saturday, March 26, 2011! (More
on that later.)

Tech sessions
#1: Relay 109

Rain nor sleet nor snow nor wind nor a bad running TDI
will ever keep our resident mail carrier, Frank Preuss, from
delivery good tech info to our membership. Frank graced us
with an explanation of Relay 109
Test relay 109 by turning ignition switch to on. The glow plug
light should light up if relay 109 is Good. It will only light for
1 sec or 2 then go out.
Just for laughs I tried to trace all the things that Relay 109,
(aka J317-Power Supply (Terminal 30, B+) Relay) powers.
This is what I came up with:
N108-cold start injector
N75-Wastegate Bypass Regulator Valve
N239-Change-over valve for intake manifold flap
N18-EGR Vacuum Regulator Solenoid Valve
G70-Mass Air Flow Sensor
J52-Glow Plug Relay
F36-Clutch Vacuum Vent Valve Switch
F47-Brake Vacuum Vent Valve Switch
F-Brake Light Switch
N79-PCV Heater Element
J359, J360-Relays for Preheating Coolant (coolant glow
plugs)
N146-Quantity Adjuster
G149-Modulating Piston Displacement Sensor
G81-Fuel Temperature Sensor

E45-Cruise Control Switch

E227-Button for Cruise Control (set)
J248-Diesel Direct Fuel Injection Engine Control Module
On the A4 (1999-2004) VW, above where the clutch, brake,
and diesel pedals are, there is a plate that must be removed.
There are 3 torx screws holding it in place away from the
firewall. On the firewall there are two white plastic things that
hold in place that end of the plate - dont mess with these the plate slides out of them - just remember to properly slide
the plate into them when putting the plate back into place.
1. adjust drivers seat all the way back
2. remove the above-mentioned plate
3. lying down under the dash you will see the relay 109
3. remove the large relay that is in the way
4. remove relay 109
5. insert new (grey color) relay 109
6. insert the large relay that was in the way
7. slide plate into the two white things at the firewall
8. install the 3 torx screws

#2: Changing a serpentine belt

Well, it sounded easy enough when I volunteered to

demonstrate how to change a serpentine belt. I had done it
before when changing my timing belt, and I remembered it
being easy, but
The Bentley shop manual lists using a 15mm socket.
Change that to 16MM on some models including my 2002
Jetta wagon. The space between the frame (unibody)
and the belt tensioning mechanism is rather tight. Using
a serpentine tensioner tool (a long, flat bar with a 3/8
square drive on the end) revealed that the shallow 16mm
socket must be shallower than most sockets, that is, not
to exceed 3/4 in length. I had one with my tensioner lever
but somehow misplaced it. I bought an old, used 3/8-drive,
12-point, shallow 16mm socket and ground it down a bit on
each end. If you dont have a serpentine tensioner tool you
can make one (if you have access to a welder) by using a
flat, 1/4 thick by 1.25 wide (or wider) steel bar about 2436 long. Drive a hole in one end large enough to insert a
short, flat piece of 3/8 square steel, which is then welded
into place from the back side.
Youve got a low-cost bar thats great when leverage is
needed. As long as youre at it, attach piece of 1/2 square
stock on the other end and have yourself a lever for 1/2drive sockets!

#3: Water leaks inside?

One topic that was going to be discussed but slipped

through the cracks was one way to reduce the probability of
water getting into your VWs front seat area.
Unfortunately, VW has a reputation for leaky door seals on
some of its cars. I had one seal changed on my Jetta in the
first year of ownership. When water started appearing in
the foot well again I got concerned. But further investigation
revealed that the water was coming from under the dash,
not from around the doors!?? Close inspection revealed
that water was entering around the kick panels under the
dashboard. Further investigation revealed that leaves
that got into the cowl area near the windshield wipers had
gravitated down into the pocket between the front fender
and the inner structure. Removing the bolt holding the
bottom edge of the fender allowed me to pull the fender out
enough to gain access to the built-up leaves. They were
piled up about 16 inches high! In less than a minute the
leaves were gone and my wetness problem disappeared.
Apparently the leaves formed a dam and rainwater coming
down from the cowl area hit the leaves and was diverted into
the interior.

#4: Trailer brake controller

Some folks at the GTG showed interest in how to install
a brake controller in a TDI. A brake controller is an
electronic device that actuates the electric brakes in a
trailer being towed. When the pull vehicle slows down the
brake controller sends proportioned voltage to the electric
brakes in the trailer to assist the pull vehicles brakes in
stopping the car-trailer package. The brake controller uses
a decelerometer to sense how quickly the pull vehicle is
slowing down and sends a proportionate amount to the
trailer.

The system used in my installation is a four-wire system,

which is common to many brake controllers. One wire goes
to ground. Another wire gets 12VDC from the battery (or
other power source in the cars electrical system). The third
wire connects to the brake light switch or wiring. The fourth
wire carries power from the controller to the brakes in the
trailer.
Investigation revealed the best location for the power from
brake lights was in the rear of the Jetta where the brake
lights are fed to the trailer (a hard-top travel trailer in this
case). Wiring directly from the under-dash brake switch of
the VW doesnt work as the wiring goes through the ECM
or other electronic device under the dash, so the brake light
wiring at the rear of the car is the best choice.

Installation takes a few hours but saves over $150, so at

$30-$50 an hour, Ill do my own installation, thank you.

NEXT TDIGTG MEETING

SATURDAY, MARCH 26, 2011

The focus of our next GTG will be auto body repair and
painting. Weve discussed doing this before but, quite
frankly, this is a topic that can consume a six-month tech
school semester (at a minimum), so one day?? But so many
have asked for this topic that were going to give it a good
shot.
Discussion will cover (at a basic level):
Banging out dents when to do and when not.
Preparation before painting:
o Hammering
o Grinding
o Sanding
o Welding auto bodies: yes & no
o Masking tape procedures
o Priming
o Finish sanding
o Block sanding
Basecoat clearcoat
Spray gun operation, use & clean-up
Painting safety
Compounding & buffing

How Do I Register for

the March 26th, 2011
GTG in Ocala?
We do require pre-registration for all GTGs so that we
may prepare the correct amount of food, beverages, snacks
and handouts. Registration is now $6 per person. You can
either phone us at 352-694-3705, 352-572-8421, or email
us at doctordiesel@cox.net. Registration opens February
1st, 2011 and ends Tuesday, March 22nd. You must be
registered by March 22nd!

Special thoughts

Special prayers and thoughts are asked for Patricia Raissis

Pete Raissis, shop foreman at Gunther VW and Central Florida
TDI member, has been a loving husband and soulmate to his wife,
Patricia, as she battles cancer. We ask that you include her in your
thoughts and/or prayers as she fights against this disease. Thanks
in advance for your caring.

Your VW OEM
discount parts
card is here!44
If you have any questions
about each companys
discount program, contact
them directly via email or
phone call. Print this page and
cut out the card at right. Fold
it and keep it handy for future
savings.
We appreciate the help of
Pete Raissis of Gunther VW
and David Farnham of VW of
Ocala for their cooperation
and assistance in making this
goal a reality.
Feel free to share this
information with other VW
owners and/or shops.

All www.Tdi Club members can

get 20% off list price on parts. To
order parts online visit our website
at www.gunthervw.net, order parts
from the service and parts tab. At
the end of the check out write TDICLUB in the coupon box . The 20%
discount will be subtracted from
the total. Write your Tdi Club user
name in the comments box. Once
your user name is verified your
order will be processed.

To order by phone call parts direct

at 954-590-3840 or use the dealer
main toll free number at 888-8461676. State you are a Tdi Club
member to the parts person to get
the 20% discount.
Note: The 20% discount is for Tdi
Club member personal use. If
you are a business please start a
business account with us.

All ww
get 20
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20% discount to cf-tdi members on

just about all parts excluding trim (seat
panels and stuff like that). Also discounts
on maintenance items. Keep in mind
some items have a short mark up on
them; giving 20% off on those items
will cause us to sell items below cost.
Since thats not practical, I will do cost
+10% on just those items. This should
ensure better pricing than found online.
Re: freight Any additional
charges will be 5% over invoiced
part. Usually a stock order is 2 business
days, but we can & will accommodate
special needs situations, i.e. car down
type stuff. Contacts: at
dfarnham@gettel.com or MonteCoates at
mcoates@gettel.com

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See yall in Ocala

SATURDAY, March
26th, 2011! Bring a
friend, too!

How would this affect YOUR rates?

Got some repair ideas to share with other

TDI owners? Bring them to the next GTG
in Ocala on Saturday, March 26, 2011.
Cant attend? Drop us an email with
specifics, and be sure to include your
name, email and a contact phone number
in case we need to get some more facts
for publication in our newsletter.

Reprinted by popular demand,

courtesy of Lew Gresham