My Mk4 Golf GTi

[Jekyll]

Love the updates/write up.

Fair play for always having a go at things. Enjoyed it when you did it to the Clio too

 

[M90SR]

Some minor updates
Decided to pull my finger out and get to work on getting the car to the way I want it.
New shark fin aerial made a huge improvement to the aesthetic, function wise its about 75% performance/range of the normal antenna.
OLD:

NEW: I know this isnt the best pic

Also want to get the sound system the way I want it. Rather than routing cables by tucking them under trim, I will be stripping the interior right to the shell and re laying the cables.
Its the longest but easiest way of doing a system as complicated as I have planned. All ready for CS though! :smilingimp:

Also bought some Bora High line interior vents which look wayy more modern than the original. They are expensive for what they are but a popular mod and I can see why.

ORIGINAL:

NEW:

 

[welshname]

Looking good. I love how interchangeable the mk4 platform is

Sent from my Nexus 6P using Tapatalk

 

[M90SR]

Well unfortunate sad news regarding the Golf...

The engine blew out on me so yeah I guess that's the end of that...

Full rebuild to follow, hopefully it gets done before CS16

 

[_Tom]

How did it "blow"?

 

[DaveDreads]

NOOOO!!!!! I f*cking love this car, you have to fix it!

 

[Euan94]

Not good mate, hope you can still bring it along to CSF!

 

[M90SR]

How did it "blow"?

I have yet to take the block apart but...
- Before the engine went I heard a metal on metal sound (the timing belt was fine and did not slip)
- Compression testing revealed 200 psi on Cylinder 1-3, however cylinder 4 was 35 psi
- Using the 'oil down the spark plug test' it was narrowed down that the piston ring was 'fried'.
- When draining the oil the first half of it was anti-freeze before the oil came out (indicating a possible cracked head/block)

Fortunately I have bought another engine to which I will use as the replacement. With massive thanks to @STEVE.M for helping me with the engine swap and fault finding. Like I said earlier in the thread I like to try things myself and learn so this a HUGE learning curve :smile:

 

[msremmert]

I really love this generation of VWs.
Considered sticking a W8 dome light in there as well?

I bunged one in my Passat and the cabin lights up a dim red at night when the headlights are on

 

[M90SR]

I really love this generation of VWs.
Considered sticking a W8 dome light in there as well?

Maybe...
I want to re trim the headliner black and I'd have to by a black dome light so I doubt I'd be able to.

 

[msremmert]

Maybe...
I want to re trim the headliner black and I'd have to by a black dome light so I doubt I'd be able to. 😧

Spray it black like the rest of us gypsies!

 

[M90SR]

Its been about 12 days now, since the engine sh@ itself.
Been a hectic 12 days constantly working on the car after work, wouldnt have it any other way.... well having a working car would be alright.

Day 1: Engine sh@ itself
Compression tested the cylinders, 200 PSI, 200 PSI, 200 PSI and then..

Cylinder number 4 is the issue, now what is wrong?
Further testing indicated it might be the Piston Rings so the engine was coming out.
Day 2: New Engine bought

VW AUM Engine slightly different to mine but intend to use the Block from it, bought cheap on a Sunday delievered within 40 minutes cant complain.
Day 4: Car Jacked up, started to unbolt and un-wire things

All fluids drained
Day 5: Wires,pipes almost fully removed and radiator removed

Day 6: Engine Removed

Day 7: Engine Ancillaries Removed

Day 8: Gearbox Removed

Day 9: Blown Engine dismantled to see what went wrong
Head removed and Pistons 1 and 4 should be top dead centre (TDC) and...

Something clearly wrong here!
Taking the sump off revealed:

Shredded teeth on the Crankshaft sensor ring thingy. Which explains the grinding sound hear before the car died. Now what was grinding against it??
Well no surprise:

Going to make a nice paper weight, but I'll leave that for another thread.
What had happened was the Headgasket for some strange reason perished slightly allowing water to come into the block and was gradually filling it up. Eventually there was so much water and no where for it to go the Engine Hydro Locked and Bent Rod No.4.

More pics to follow as soon as I take them.

 

[M90SR]

Long time no update...
Well its been 2 months since I last updated and I have good news to say the car is up and running. I'll continue the write up including pictures of the process
Cleaned up the pistons while they were out:

Cleaned up 75% didnt do a 100% clean pic

Sprayed the block with some Engine paint matte black

Sprayed the rocker cover

Pistons in the block

New bearings

Crank in

General assembly of block

Cylinder 1 and 4 at TDC

Timing bits

Head

Cams in

Looking so much like an engine now

Timing Belt

Silicone piping for turbo

Timing covers

And after a long day the engine in the car

Done about 150 miles in the car so far. Taking it relatively easy at the moment. Cars taken off the road until 25th Septemeber for TRAX.
In the mean time I'll be fixing up the exterior and some cosmetics of the car.

 

[DaveDreads]

Good work, glad to see it lives again, i'd love to be able to engine swaps and rebuilds, are you a mechanic?

 

[M90SR]

Good work, glad to see it lives again, i'd love to be able to engine swaps and rebuilds, are you a mechanic?

thanks dude.
I am an engineer at heart so will take anything apart and put it back together lol.

 

[DaveDreads]

Taking it apart wouldn't be a problem for me, putting it back together and making it work on the other hand....

 

[STEVE.M]

thanks dude.
I am an engineer at heart so will take anything apart and put it back together lol.

Well done.
I still cannot get my head around big end shells without ears to stop them spinning.

 

[M90SR]

This build would have not have been done if it wasnt for the help of @STEVE.M incredible learnt so much and without his help dont think the engine would of started first time.

 

[AdDaMan]

I thought you said at the start it was forged?!

 

[STEVE.M]

This build would have not have been done if it wasnt for the help of @STEVE.M incredible learnt so much and without his help dont think the engine would of started first time.

Thanks for the acknowledgement,but I just advised.It was your work that made it happen..Well done again.

 

[M90SR]

I thought you said at the start it was forged?!

Unfortunately the rods were not. I was under the impression that they were. I am not sure on the pistons though. But its back to normal now.

 

[cs_dave]

Unfortunately the rods were not. I was under the impression that they were. I am not sure on the pistons though. But its back to normal now.

Is it a bam engine? As the pistons for a bam 1.8t are forged std items

 

[M90SR]

Is it a bam engine? As the pistons for a bam 1.8t are forged std items

AGU so I guess they're not forged unfortunately.

 

[DaveDreads]

What kind of power can you get out of a 20V Turbo and what kind of money does it take?

 

[cs_dave]

What kind of power can you get out of a 20V Turbo and what kind of money does it take?

Alot more than a f4r for alot less

Rods are the only weak point so 500 ish for fordged your ok for upto 400hp with bigger turbo and better injectors

 

[DaveDreads]

F*ck me why did I ever stop driving Golfs and get a Clio?
The amount i've spent on the dog kennel over the years I could have built a doomsday 20VT by now.

 

[M90SR]

Only down side its a different driving experience. I love the go karted-ness of the Clio, the golf feels agile but not nearly as much as the Clio. It is a better build car with the doors making that 'doof' sound when you close them.
The power step ups in the Golf (from my understanding are as follows)
- Stage 1 150bhp to 180-200bhp (Remap, Intake, exhaust)
- Stage 1.5 200bhp to 230bhp (Silicone hoses, DECAT)
- Stage 2 230bhp-260bhp (KO3s turbo, FMIC, 3" MAF etc..)
- Stage 3 260bhp - 300bhp (KO4 turbo)
- Then forged, hybrid turbo, injectors, fuel pump etc.. you'll keep going up and up.
Don't quote me on the stages.

 

[cs_dave]

Gotta be the mixture of the 2 clio 1.8t cracking car

 

[M90SR]

Gotta be the mixture of the 2 clio 1.8t cracking car

Did you put the 1.8t in the clio? I see your profile pic?

 

[cs_dave]

Did you put the 1.8t in the clio? I see your profile pic?

No andyrg did the hard work buolt it for himself ive bought it then changed and messed as ive gone.

 

[DaveDreads]

Wow, seeing it in a Clio engine bay makes you realise how small and compact it is.

 

[M90SR]

Haven't updated in a while one would assume the cars been sent to the scrappy or one might assume I'd happily driving it around. Neither unfortunately.
Car is still at home and gets a tire rotation and a maintenance wash every now and then.

The plan currently is to rebuild the interior which gives me the opportunity to incorporate my sound system into the vehicle.
There was also a leak which caused the underlay behind the dash to become moldy.

So seeing as though I rebuilt the engine it only makes sense to just strip the interior and start from scratch. Essentially all I have done is create a track car, however I don't see it being a better car on track than the 182. Plus I wanna put some genuine non thrashing miles on the engine to warrant me rebuilding it.

Starts with the basics dash and carpet removal:

I then felt the need to take it for a drive whilst my first Clio (1.2 dynamique) engine replacement took place. (I blew that too....)

The looks I would get when people looked into the car from traffic was hilarious. In my opinion the car was still safe to drive, seat belt and seat secured.

Wave of the magic wand and...

Internal Cross member out

Carpet underlay

All stripped

Sound deadening for the firewall during its application

I applied baking soda to the underlay to help remove the smell.



So thats pretty much where the car stands. I have been buying loads of parts for it regardless so lots more left to document on this build.
One things for sure a car I can say I fully rebuilt and probably one of the only cars I would have the pleasure in doing so.

 

[Akay]

Love it, I had a Mk4 Golf TDI 130 after my CTR, and then again after my 182 (the same car, never sold it), despite the poor handling the engine and build quality were great imo, plenty of support and mods for them as well.