Something I've been wondering about lately: Gas powered VWs from this era, at least to hear this forum tell it, sound as if Robert Bosch may replace Joseph Lucas in "Prince of Darkness" jokes. Do TDIs have the same level of issues, or are they any different?
Isn't that timeframe of TDi diesels mechanically injected? So, I would say they have less issues motor wise, but chassis wise the same.
they are different.
The '99-'03 "ALH" motor TDI was pretty much the peak in terms of longevity combined with simplicity for the TDI drivetrain. It still uses a mechanical injection pump. They actually get slightly higher MPG's than all the TDI's '04 and newer.
The car itself is still a mkiv VW though, so the rest will have flaky issues, but it will generally continue to start/run for lots and lots of miles. Typically things like window clips and regulators fail, door latch switches fail, all the soft touch plastics will look terrible, random lights burn out all the time, etc. but the TDI drivetrains are stout. Buy a manual trans though, VW's automatics are notoriously unreliable.
My '99.5 Golf 2-door TDI 5-speed has been a trooper, and never left me stranded. I've got just over 230K on it and drive it 150 miles/day. I don't track fuelly any more as the miles/tank shows it to be consistent, but it does 45+ MPG's all day long.
http://www.fuelly.com/driver/grounded87/golf
Anything you'd ever want to learn about them can be found on tdiclub.com
MadScientistMatt wrote: to hear this forum tell it, sound as if Robert Bosch may replace Joseph Lucas in "Prince of Darkness" jokes.
Lucas engineers don't die. They cross the Channel to work for Bosch.
I had a gas engine 2002 Jetta when it was new. For me, that was the worst car I've ever owned. Awful, awful car. I've always read that the TDI cars were made back in Germany while the others were strewn together at the Pueblo, Mexico plant. That might have something to do with the difference in quality, but I could be wrong.
xflowgolf wrote: they are different. The '99-'03 "ALH" motor TDI was pretty much the peak in terms of longevity combined with simplicity for the TDI drivetrain. It still uses a mechanical injection pump. They actually get slightly higher MPG's than all the TDI's '04 and newer. The car itself is still a mkiv VW though, so the rest will have flaky issues, but it will generally continue to start/run for lots and lots of miles. Typically things like window clips and regulators fail, door latch switches fail, all the soft touch plastics will look terrible, random lights burn out all the time, etc. but the TDI drivetrains are stout. Buy a manual trans though, VW's automatics are notoriously unreliable. My '99.5 Golf 2-door TDI 5-speed has been a trooper, and never left me stranded. I've got just over 230K on it and drive it 150 miles/day. I don't track fuelly any more as the miles/tank shows it to be consistent, but it does 45+ MPG's all day long. http://www.fuelly.com/driver/grounded87/golf Anything you'd ever want to learn about them can be found on tdiclub.com
Mine hasn't really left me stranded, but I did have to push start it for a week (ignition switch). I'll agree with what this guy said, with heavy emphasis on VW issues. One thing I may disagree on is the transmission. My mom has the auto and its been flawless. They synchros on my car (00) and my sisters (04) are both on their way out and arent the easiest to shift.
SilverFleet wrote: I had a gas engine 2002 Jetta when it was new. For me, that was the worst car I've ever owned. Awful, awful car. I've always read that the TDI cars were made back in Germany while the others were strewn together at the Pueblo, Mexico plant. That might have something to do with the difference in quality, but I could be wrong.
My TDI was built in Mehico.
In reply to SilverFleet:
From what I remember, the only MkIV's sold in the US that were consistently made in Germany were the wagons. Most Golfs and Jettas came from Mexico. That said, the guys on tdiclub who work on these cars all the time say there is no coorelation between the assembly plant and overall reliability. It's basically a crap-shoot. The Germans were just as likely to produce junk.
Ian F wrote: In reply to SilverFleet: From what I remember, the only MkIV's sold in the US that were consistently made in Germany were the wagons. Most Golfs and Jettas came from Mexico. That said, the guys on tdiclub who work on these cars all the time say there is no coorelation between the assembly plant and overall reliability. It's basically a crap-shoot. The Germans were just as likely to produce junk.
Good to know! I knew the wagons were built in Germany, but I was always told the TDI's were too. Either way, mine was an epic turd and I was very happy to see it leave my posession. 
I have a 2001 Golf TDI that had little evidence that it had been loved in the 60k miles the car was driven before I bought it. I had the timing belt and related hardware done by a TDI guru, and have proceded to put another 80k miles or so on it without doing anything more than tires and brakes. I love it - 50mpg almost every tank.
Drove a '01 ALH Beetle for 6 years and 100k+ miles. The drivetrain was as solid as the day I got it when I sold it but the electronics were junk. Always throwing a code for something or developing a random gremlin. I would have kept the dang thing but the Beetle body style necessitated the worst possible mechanic-friendly design. I'm not sure if it's the same for the Golf/Jetta platform, but it was all but impossible to work on the car in that cramped engine bay and I didn't have the resources to change the timing belt myself, which is a very costly maintenance item.
Get a code reader/clearer, use the best oil you can find and if you can live with the little quirks they will run forever. I even towed a small trailer with motorcycles all over with mine and it loved it.
Have owned a 2000 mk4 jetta TDI since 08 bought it 124k miles on it just turned 175k miles on it no issues at all. Do oil changes every 10k with oil change kits from TDIparts.com (now IDparts.com)
43mpg steady doing my commute at 80mph, if I drop to 70 it goes to 45, if I use fuel additive it also goes to 45 but its a wash cost wise.
I got mine with rollup windows and a 5 speed so most of the things that go wrong are just not there
Thanks to everyone who replied! Lots of good info here, and I don't want an automatic in my daily driver anyway.
99-early00 and then ok again sometime in 03 ad far as that body style and electrical/engine management support part problems go.
My 03 Jetta just hit 270K miles, Its been hot-rodded to about 130 HP, still on original clutch and turbo. Had to replace inj pump seals and add a lift pump in the fuel tank this year due to air in the fuel system. Injectors are probably dirty, can hold the peddle to the floor and not get much smoke. Gets 48-50 MPH if I keep it below 80. It uses about a quart of oil in 5000 miles. Waiting for the new GTD or GTI to come to the states.
They're very reliable because I have been trying to buy one at a good KBB price for TWO years and no one wants to give me a good price on one. 
People hold on to them since they don't have to worry about an electronic ignition system that plague the gas versions. I may have to settle for an early 90s Mercedes diesel next year.
Will be watching this thread with interest as I bought a Black/Tan 2000 Jetta TDI about a month ago w/285K. Got 49.3 MPG on the only tank I've checked, so far. Everything works except A/C doesn't blow cold and I have a CEL for glow plug circuit which I haven't bothered to check, yet. I really hope this thing holds up, because so far I love it and am getting really used to the fuel mileage/reasonable comfort combination.
I've had mine for 5+ Years and done nothing to it but oil changes and a few shifter mods and a mild chip. I got it at 180k and have 215k now, it had a new factory clutch at 180k and it's still on it and feels new still. I do a lot of highway though I have a lead foot and set the cruise at 80, but have been known to be late for work and had to do 90-100mph for 15 mins, still gets 38mpg no matter how hard I drive it, 60% hwy miles, Most of the time it gets 45mpg, 2000 Jetta 5-speed, I'm ready to move up to something sportier and won't overcharge for it you guys are still interested PM me, I'm in upstate NY.
carzan wrote: I have a CEL for glow plug circuit which I haven't bothered to check, yet.
Sometimes replacing the glow plugs will fix it, but it seems it's usually the wiring harness. It's a bit fiddly to R&R, but not terrible. The connector is buried under a panel behind the air box, so a few things have to come out. Plus, it's wrapped with other parts of the engine harness, so you have to unwrap it and re-wrap. Get some cloth harness wrap before starting.
Ian F wrote:carzan wrote: I have a CEL for glow plug circuit which I haven't bothered to check, yet.Sometimes replacing the glow plugs will fix it, but it seems it's usually the wiring harness. It's a bit fiddly to R&R, but not terrible. The connector is buried under a panel behind the air box, so a few things have to come out. Plus, it's wrapped with other parts of the engine harness, so you have to unwrap it and re-wrap. Get some cloth harness wrap before starting.
Thanks Ian. That's kinda what I figured. That's pretty much why I haven't started digging, yet.
In reply to carzan:
I replaced the glow plugs twice before replacing the harness. New glow plugs would usually give me a few months but the new harness has lasted longer than the original one.
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