MK5 Golf GTI

All Things Mk5 => Members Rides => Topic started by: LC5F on October 20, 2019, 07:26:02 pm

Title: LC5F's Graphite Blue GTI - Pilgrimage to Caffeine & Machine
Post by: LC5F on October 20, 2019, 07:26:02 pm
Just upgraded from MK4 Gti to a DSG Graphite Blue Mk5 Gti - Really like the changes VW made
(https://i.vgy.me/QBOvDH.jpg)
Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on October 24, 2019, 09:12:08 pm
So a bit more about my Mk5
Battery was struggling - considering its condition and it was genuine VW it had to be replaced:
(https://i.vgy.me/jz5Cez.jpg)
Gave it a service - eveything but oil:
(https://i.vgy.me/OOBQts.jpg)
Spark plugs looked really manky - how often are these meant to be changed?
couldnt see any record of it happening...along with brake fluid.

Now for something really random hiding in the boot, still struggling to understand why whoever it was did this??:
(https://i.vgy.me/x4P1m3.jpg)
to my displeasure they had even scotch blocked ito the cars loom:
(https://i.vgy.me/E4SW0f.jpg)
Powering this thing was a red cable tucked under the sill cover to the fuse box:
(https://i.vgy.me/ia4z23.jpg)
Now binned:
(https://i.vgy.me/d2iYCF.jpg)
All thats left is the fuse holder, will tidy that up next time the battery is off.

The other thing that happened was the thermostat, reading up it said it was a 3 hour job, it took me and a friend 7 hours in the rain to sort, the good news was this allowed the engine temp to sit at 90 and high fuel consumption improved.

Things still to sort -
Big cooling fan is on all the time, going to look into that this weekend.
It came with a non-resonated 3" Cobra exhaust fitted, the pops and bangs and DSG shifts are great, but it just dronnes on the motorway + its missing its exhaust tips (WTF?) - so its booked in to get resonated and new tips start of next month.
Passenger slide and tilt - I have the plastic clip, just need to work out how it fits

No real plans to make changes, but these popped up on ebay and were too good to ignore:
(https://i.vgy.me/n8jrYr.jpg)
Title: Re: LC5F's Graphite Blue GTI
Post by: Mark_DF05 on October 26, 2019, 05:32:24 pm
What was that in the boot?
Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on November 05, 2019, 08:09:49 pm
It was a trailer light plug - think a PO had a bike rack, this screwed up the panel gaps on the hatch too.
Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on November 17, 2019, 01:10:15 pm
Swapped out the crusty hatch:
(https://i.vgy.me/cNnJk0.jpg)

Think its had replacement glass at some point, the sealant doesnt look OEM, probaly cutting wire knicked the paint:
(https://i.vgy.me/h87fCY.jpg)

Replacement hatch on - I was having a few issues with condensation, I assume a PO had a bike rack that pulled the hatch out of alignment and making a leak - this seems to have been solved with the new hatch. Just need to remove the super glue someone stuck badges on with:
(https://i.vgy.me/asymiK.jpg)

Cat back Cobra was ridiculously loud and was missing tips, a morning at local stainless exhaust shop, resonator and tips added - a lot more civilised now
(https://i.vgy.me/KfAA7K.jpg)
Title: Re: LC5F's Graphite Blue GTI
Post by: burtz on November 21, 2019, 03:42:12 pm
Nice work!
Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on November 30, 2019, 04:14:55 pm
Nice work!

Cheers!

Busy morning, after getting the correct filter housing socket I got to flush and renew the oil + reset the service setting, found out the sump is slightly cross threaded, but it going in with care and feels tight.
This was followed by a modile tyre fitter turning up to fit new boots:
(https://i.vgy.me/hQeVVn.jpg)
Rainsport 5 - never tried them before, it rains a lot in Scotland so makes sense.
Coming off were Conti Sportcontact 5's, they seemed to have lots of meat still on them, but were under steering and wheel spinning everywhere.

Replaced these with jack pads -I didnt take pictures it was minus 2:
(https://i.vgy.me/5HaiGW.jpg)
I was thinking of fitting these to my Mk4 but never got round to it - some garage numbnut managed to damage a sill. So I decided for the mk5 I would invest in some OEM jack pads.
Not sure how old the prices are listed in the forum mods list, but from TPS they were super pricey.
Fitting was awkward and they don't feel as solid as I was expecting and the front ones are a long way inboard.
Maybe I need to experiment, but my jacks wheels block getting axle stand under the rear control arm globe housing.

Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on December 12, 2019, 10:14:39 pm
One one thing I need to do is rebuild the front calipers - under repeated heavy breaking it feels like warped discs, just something binding.
Rather than disable my daily by take the current calipers off, strip-down, repaint & rebuild I like to get another set to do off the car.
I managed to source a set, with cariers and pads off ebay, looking at the condition, I have to say I had a double take on the listing and I cant believe how good they are in the flesh:
(https://i.vgy.me/aWUrmH.jpg)
They look like they are very nearly new! carrier bolts nearly new, pads maybe done a couple of hundred miles, no rust! -and a complete bargain, cheaper than proper "rebuild only" ones. These I confidently say they do not need rebuilding
Title: Re: LC5F's Graphite Blue GTI
Post by: kodirl on December 24, 2019, 06:09:38 pm
Great work so far. Recently purchased my second mk5 GTI 7 years after selling my last one. Will be following this , keep the updates flowing

Sent from my Mi A2 using Tapatalk

Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on December 26, 2019, 08:30:03 pm
@kodirl (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=8057) -Thanks for the kind words

Minor updates -
Sourced some rear calipers to rebuild, sadly they in a lot poorer state than the fronts:
(https://i.vgy.me/NKMe57.jpg)
Not exactly classically pretty, more fugly!
(https://i.vgy.me/NvCuCm.jpg)
They were a struggle to strip down, but they both came apart, even the bleed nipples came out in one piece.
Pistons were jammed, there was some slight scratching of the bores as I encouraged them out- they will need a hone to tidy up - by sheer coincidence I got a hone tool for Christmas!
Need to strip the last of the paint, remove the oxidation, paint and rebuild with new pistons and seals.

Another Christmas item to myself:
(https://i.vgy.me/84Imwk.jpg)

Neuspeed P-Flow  - Would have preferred boring black, this has been mucked around, has an AEM filter and the silicone hose to the turbo is not Neuspeed.
First impression is a restriction has been removed, even at low speeds
No cover now means I will have to get busy with the TFR on the bay.

Title: Re: LC5F's Graphite Blue GTI
Post by: terrier on December 26, 2019, 08:53:22 pm
do you have the Rainsport 5 fitted and how are they doing. :happy2:
Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on December 26, 2019, 09:19:31 pm
do you have the Rainsport 5 fitted and how are they doing. :happy2:

Yes - I recommend, they are very good, I find them to be very sure footed in the wet - last time I felt this level of grip in the wet was 4 wheel drive in my old ur-quattro back in the 90's!

They claim to have shark skin technology, this is a rough surface at the base of the grooves that helps cut through the standing water  -I was sceptical- but it works very well, none of the steering being wrenched as you hit a puddle, loss of traction or wheel hop, it just keeps gripping.

Another plus is they seem to produce a lot less spray being lifted up - if you are by yourself the rear screen keeps pretty clear - but sharing a motorway on the commute you get everyone else's spray! HTH
Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on February 23, 2020, 09:00:42 pm
After an impromptu trip to Wales Golf was looking pretty grim:
(https://i.vgy.me/w4A9jO.jpg)

Return back to Scotland, with pressure washer is packed away for winter, so out of convenience I committed car guy heresy by chucking it through the automated car wash:
(https://i.vgy.me/tsiJkV.jpg)

Thought the result was pretty good.

Rear calipers finally got sorted, biggest problem was getting rid of the old powder coating, didnt want to dig out the my sand blaster + the finish after blasting isn't that great.
Nitromors didn't work - so I invested in something more industrial, Starchem Synstrip - this worked, but very slowly.
The alloy corrosion also wasn't shifting, after trying all sorts of stuff I found Mr Muscle drain cleaner - the oxidation just fizzed off.
Halfords red brake paint was disappointing, it took several layers to build up to actually cover the bare alloy, liked to drip and after several days it just started dissolving with brake cleaner!
Still got to make the short pipe from the caliper to flexi, but I am reasonably happy with the result:
(https://i.vgy.me/lkL4AK.jpg)

 
Title: Re: LC5F's Graphite Blue GTI
Post by: terrier on February 23, 2020, 10:03:48 pm
how did the rainsports perform on the trip to Wales :happy2:
Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on February 29, 2020, 07:01:40 pm
how did the rainsports perform on the trip to Wales :happy2:

They performed very well - they highlighting the bush wear in front control arms - Superpro anti lift bush set on alloy arms will be incoming once the weather sorts itself out.

Rain stopped this morning, managed to replace the perspex plates for pressed plates and fitted a turbo heat shield under the induction kit.

Finished off the rear calipers:
(https://i.vgy.me/4FSVMu.jpg)

It seems a shame to go to the trouble of fitting brass fittings with Cunifer pipe onto a really bad paint finish - half tempted to strip them back down and get them powder coated.
Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on March 08, 2020, 04:22:16 pm
managed to spend some time with the Mk5 -
Finally got round to changing the inline thermostat above the DSG box, my clips were on the bottom and the clip pliers needed a huge amount of space to open them up, only lost half a cup of coolant but its all back together - old thermostat was jammed open.
Did a partial upgrade of the screws holding the undertray on, stainless Audi screws from my last scrapyard trawl:
(https://i.vgy.me/oKsphN.jpg)
There was only 3 screws holding it in place, the clips the screws go into were near failing - Need to source another 4 clips and fine thread screws to fully fix the panel.


Got my hands on some 6K LED side lights, I forgot they need to be put in to suit the current flow... put the nearside fully back together, then remembered.... They match the Xenons nicely, this was a dreich nnight in gentrified Edinburgh:
(https://i.vgy.me/Ex2I6L.jpg)
Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on March 13, 2020, 08:44:18 pm
I had been mulling over suspension for the Golf, I had B14 coilovers on my previous Mk4, they were really good but it seems Brexit has made the same for the Mk5 a bit too pricey for a daily.
My othe VW came with AP coilovers and are really good, so plumped for a set up for the Mk5.
They are currently on their way from europe, at a really good price, even with delivery they are a big chunk off UK retail
- only rub is they are coming from Naples Italy...despite the lock down UPS says they have just left Milan.

Got myself new lemforder top mounts all round + new bolts from TPS

And then these turned up:
(https://i.vgy.me/psRf0N.jpg)
Front and rear subframe aligners, I have no ETA for installation, come with pretty good instructions.
They are similar to the tyrolsport ones with a piece for the top and bottom - dont think they do the rear subframe?? - but they don't have the cup that the bolt head sits in
They look really good - made sweeter by a mix up, no import tax - not bad for just over £30 and 6 weeks to get here
Title: Re: LC5F's Graphite Blue GTI
Post by: shannon-ob on March 20, 2020, 01:38:14 pm
Great price for the subframe kit!

Where is it from if you don't mind me asking?
Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on March 20, 2020, 07:41:04 pm
Great price for the subframe kit!
Where is it from if you don't mind me asking?
No problem - Aliexpress, its gone up in price a bit: https://www.aliexpress.com/item/4000344800378.html?gps-id=ru_edm_recommend&scm=1007.25755.141389.0&scm_id=1007.25755.141389.0&scm-url=1007.25755.141389.0&pvid=8029187e-beb4-4bc2-a082-1d9c9a445ad5&userTouchChannel=targetEdm&smiId=biz_add_cart:1002:5baa98ca616c47d99b13a6f30e505506&tracelog=rowan&rowan_id1=houyi_target_edm_1_en_US_2020-01-26&rowan_msg_id=8098biz_add_cart:1002:5baa98ca616c47d99b13a6f30e505506_69378$f25f023504a6411581ebae22bde34176&ck=in_edm_other

Been putting off fixing my mirror indicators till I got daylight, watched a couple of Youtube videos and there was no excuse, dived in and it was pretty easy - quite an ecosystem I was rolling with:
(https://i.vgy.me/mIsI6W.jpg)

Decided to keep the inpro indicators - thats better:
(https://i.vgy.me/TIFXKs.jpg)

I am now fully prepared to socially isolate:
(https://i.vgy.me/DS4h6W.jpg)
Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on May 23, 2020, 02:12:29 pm
These dropped into my lap
(https://i.vgy.me/myapja.jpg)
Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on June 14, 2020, 10:42:27 pm
So the wifes dead car finally got picked up and I could dive into the Golf, the plan was to just to do coilovers, rear control arm bushs and brakes:
(https://i.vgy.me/HW0ICI.jpg)

Seems I have the Seadweller edition, everything is crusty, everything faught me:
(https://i.vgy.me/JeJ8nV.jpg)
(https://i.vgy.me/TrfCrj.jpg)
(https://i.vgy.me/I51yef.jpg)
(https://i.vgy.me/DuXUnN.jpg)

I tried undoing the Drivers ball joint and 2 out of 3 nuts sheared off and the base plate was so corroded it took a dozen hammer hits to split it from the control arm - after that I just got busy with the angle grinder:
(https://i.vgy.me/XekSJl.jpg)

Biggest problem is the 16mm control arm console bolts, 3 out of 4 sheared - I tried backing them in and out and lots of lube they still sheared. After getting them off I even tried chucking them in the oven melting candle wax - they are just stuck in there:
(https://i.vgy.me/OMbTGk.jpg)
This is the point where it turned into a full front end rebuild-
Ordered replacements off ebay - unfortunately they are both being couriered by Hermes who seem to be more useless than normal-
Drivers side has spent the last 4 days sat in Liverpool, the passenger side has been sent back to the sender....
Ended up ordering another passenger side and got it next day, now wishing I got both sides.

Passenger side CV decided to split itself as the strut came out - turned out the spring clip was worn, not installed properly, so not me pushing too hard, Drop links were completely seized, had to cut them off and grind off the nubbin sill in the ARB:
(https://i.vgy.me/XG3ovy.jpg)

CV grease was really dry, so cleaned it out and got a new boot, weird thing was there was even rust in the joint:
(https://i.vgy.me/XGJL27.jpg)

With the Passenger subframe side delivered, there was no reason not to install my Chinese dead set kit, only one insert wasn't going home, just opened out the hole and its now good:
(https://i.vgy.me/6vlPFl.jpg)

This also brought forward TT Alloy control arms and after some wrestling I managed to get a corner done:
(https://i.vgy.me/iJmbJf.jpg)

Still waiting on Drives side subframe, I swapped out the rusty steel T20 arch liner bolts for Audi stainless ones, cleaned out the lower wing - not the biggest deposit, but pretty impressive compost:
(https://i.vgy.me/F1Ia3C.jpg)







Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: agmac on June 15, 2020, 08:48:50 pm
Great story here - keep it coming though some of the pics not filling me with joy - I too live in Edinburgh, so the same crap roads and weather. I must get the wheel arch liners off to have a proper look underneath and could fairly do with a set of those front headlights - the standard headlamps are so bad they are unsafe in winter.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on June 15, 2020, 10:21:48 pm
Great story here - keep it coming though some of the pics not filling me with joy - I too live in Edinburgh, so the same crap roads and weather. I must get the wheel arch liners off to have a proper look underneath and could fairly do with a set of those front headlights - the standard headlamps are so bad they are unsafe in winter.

Hey fella - glad to find another Edinburgh roads sufferer! -
I found the Golf on Gumtree in Aberdeen, the PO used to park right down near the docks, lots of see air + not much mileage = everything just got crusty

The Drivers side subframe turned up today, after 9 days without a car my house was running low on provisions (read that as Beer for me!) - I used that as motivation. After a quick wash of the new part I assembled the control arm, the same bolt hole had to be opened up and I had opted for PSB bushes instead of Super Pro:
(https://i.vgy.me/fxvKNy.jpg)

Drivers side was a lot more difficult to align up the 3 main 18mm bolts, took a lot of adjusting but they all finally bolted up. The scrap pile got a bit bigger:
(https://i.vgy.me/UFh41y.jpg)

The debris field was pretty good too:
(https://i.vgy.me/UV9l7O.jpg)

After a big shop this evening - the beer mountain has been reinstated - I now feel brave enough to dive in and do the rear springs, shocks and the dead set bushes - but first thing I need to get an alignment done - my aligned by eye it wasn't bad, steering wheel only out by 5 to 10 degrees.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on June 17, 2020, 07:42:14 pm
Weather picked up and I tackled the remaining rear end stuff

The springs and shocks were installed without issue
(https://i.vgy.me/9i13Ez.jpg)

My rear Left arch liner is a bit baggy - is that normal?

The rear dead set kit was really easy to install... 2 bolts on each side and a bit of levering - front ones would have been even easier if I had done it with the spring and shock off.
(https://i.vgy.me/9i13Ez.jpg)

This is how its sitting, desperately needs a wash
(https://i.vgy.me/RGPjQe.jpg)
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on June 18, 2020, 07:37:34 pm
Got my chance to give the Golf its first hand wash and polish, got the washer out. first pass was TFR and a pressure wash, second pass with dodo juice snow foam:
(https://i.vgy.me/M0pZJY.jpg)

A deep clean with the suds and then rinse, then 2 bucket method with Mer shampoo and followed by Mer polish with buffer - I need to upgrade these - Wheels then got a clean, dug out some Dirty Jok's wheel cleaner I've had for years and got busy, last thing I did was rainex glass cleaner -
(https://i.vgy.me/RRVZls.jpg)

Exterior wise the last thing is the exhaust tips that had been developing some really crusty bits:
(https://i.vgy.me/u5CQ30.jpg)

I found a really good solid cleaner for chrome and aluminium called Vistal, Autosol is good but this stuff works quicker
+ it cleans and leaves a protective film - this is after a rinse, the beads are the film doing its thing - first pass - more work required:
(https://i.vgy.me/Rrq7te.jpg)
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on June 21, 2020, 12:03:50 pm
Engine bay looking a bit sorry for itself, bonnet sound deadening sagging and all the grime collected form the engine cover still there.
Had to cut off 2 of the top mount bolts for the suspension swap - I couldn't get the wiper arms off, the tool I got wasnt big enough and broke  - I was replacing the scuttle cover anyway - so it just got destroyed...
(https://i.vgy.me/S26Ggt.jpg)

After degrease and steam
(https://i.vgy.me/x5f4BE.jpg)
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 02, 2020, 08:33:31 pm
Finally got my wiper arms off - battery terminal remover worked very well - bit of a squeeze to get on. The arms popped off with such force this has to be the first time they have been taken off. Cleaned the scuttle:
(https://i.vgy.me/LDlBT1.jpg)

Had my first trip to a scrap yard since covid, managed to get a new rear arch liner - old V newer
(https://i.vgy.me/lw384i.jpg)

Only problem is the Gti liner is a different shape to suit the bumper:
(https://i.vgy.me/VPjXxg.jpg)
I just cut out the corner of the old one and put it behind the new!

Also sourced a lot better condition bonnet sound deadener, seems to be an issue as most at the scrap yard were already removed, the few still there were saggy like my old one. Deadener and scuttle cover replaced:
(https://i.vgy.me/7LxmsJ.jpg)

Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 05, 2020, 04:01:11 pm
Finally got to Halfords to get some carpet cleaner
Armed with:
(https://i.vgy.me/VWXNGl.jpg)
Rainy day here - I removed the rear seat base to have a go inside and then sun came out and had a go with the drivers seat...
Before - it seems I dribble!:
(https://i.vgy.me/lkrdsA.jpg)
After:
(https://i.vgy.me/fst8Ga.jpg)

Rain then chased my back inside - only did the drivers seat and rear seat base, they were generous, I got this out of them...
(https://i.vgy.me/5Qi3gL.jpg)
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: Deano45 on July 05, 2020, 09:05:51 pm
Great build thread and you are making some great progress....if you don’t mind me asking how are you finding the AP Coilovers? Thinking about a set myself ,,
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 05, 2020, 09:58:46 pm
Great build thread and you are making some great progress....if you don’t mind me asking how are you finding the AP Coilovers? Thinking about a set myself ,,

Thanks fella - 
I previously had Bilstein B14 on my old Mk4, I was looking into B14 for the Mk5 but I couldn't justify the price for what is a daily.  Also my other VW came with a set of AP's, I was happy to give them a go to see how they feel new.

I haven't done much mileage on them or pushed them hard, but the AP's on the Mk5 are good, they seem to be an uprated OEM feel - as described in many reviews.
Put it another way, the wife hasn't even noticed, commented or complained - I think that's a win!

BTW I got a really good deal on ebay that is still available: https://www.ebay.co.uk/itm/VW-Golf-5-AP-coilovers-Adjustable-suspensions-%C3%9855/371633207372?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649 (https://www.ebay.co.uk/itm/VW-Golf-5-AP-coilovers-Adjustable-suspensions-%C3%9855/371633207372?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649)
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: Deano45 on July 05, 2020, 11:49:07 pm
Great build thread and you are making some great progress....if you don’t mind me asking how are you finding the AP Coilovers? Thinking about a set myself ,,

Thanks fella - 
I previously had Bilstein B14 on my old Mk4, I was looking into B14 for the Mk5 but I couldn't justify the price for what is a daily.  Also my other VW came with a set of AP's, I was happy to give them a go to see how they feel new.

I haven't done much mileage on them or pushed them hard, but the AP's on the Mk5 are good, they seem to be an uprated OEM feel - as described in many reviews.
Put it another way, the wife hasn't even noticed, commented or complained - I think that's a win!

BTW I got a really good deal on ebay that is still available: https://www.ebay.co.uk/itm/VW-Golf-5-AP-coilovers-Adjustable-suspensions-%C3%9855/371633207372?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649 (https://www.ebay.co.uk/itm/VW-Golf-5-AP-coilovers-Adjustable-suspensions-%C3%9855/371633207372?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649)


Thanks Again ,, that seems perfect as I daily mine too I have herd great stuff about them it’s just nice to get a review from someone Who has recently fitted Them Ap,s are now on the shopping list ,,
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: Kebab Spider on July 16, 2020, 11:37:41 am
Great build thread and you are making some great progress....if you don’t mind me asking how are you finding the AP Coilovers? Thinking about a set myself ,,

Thanks fella - 
I previously had Bilstein B14 on my old Mk4, I was looking into B14 for the Mk5 but I couldn't justify the price for what is a daily.  Also my other VW came with a set of AP's, I was happy to give them a go to see how they feel new.

I haven't done much mileage on them or pushed them hard, but the AP's on the Mk5 are good, they seem to be an uprated OEM feel - as described in many reviews.
Put it another way, the wife hasn't even noticed, commented or complained - I think that's a win!

BTW I got a really good deal on ebay that is still available: https://www.ebay.co.uk/itm/VW-Golf-5-AP-coilovers-Adjustable-suspensions-%C3%9855/371633207372?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649 (https://www.ebay.co.uk/itm/VW-Golf-5-AP-coilovers-Adjustable-suspensions-%C3%9855/371633207372?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649)

Thanks for posting the link to the coilovers mate, £100 cheaper than any UK retailer so I've just bought a set  :grin:
Title: Re: LC5F's Graphite Blue GTI
Post by: Kebab Spider on July 16, 2020, 02:23:58 pm
Still waiting on Drives side subframe, I swapped out the rusty steel T20 arch liner bolts for Audi stainless ones

Also meant to ask you where you picked up these bolts from?
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 16, 2020, 05:22:35 pm
@Kebab Spider (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=52669) Yes - the AP's at that price seems too good a deal to say no - glad it helped!

Still waiting on Drives side subframe, I swapped out the rusty steel T20 arch liner bolts for Audi stainless ones
Also meant to ask you where you picked up these bolts from?
You can source them new - all black - for a price or just go to scrap yard and get them, usually get waved through if thats all you have.
The black covering tends to be wear off revealing the stainless.
A4's seem to have the most clips/screws I usually get a handful each trip.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: Kebab Spider on July 21, 2020, 11:29:24 pm
Cool, thanks mate. How long did your coilovers take to arrive from Italy btw?
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 22, 2020, 12:28:08 am
How long did your coilovers take to arrive from Italy btw?

Considering what was going on in Italy at the time - delivery was really quick
I ordered on 8th of March & it arrived on 17th
Seems they aren't dropshippers, it was a stock item shipped from Palma.
Tracking was good, they got it from Palma to Milan in a day or 2, then sat a few days, suddenly it was at my door in Scotland - its a great deal
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 28, 2020, 10:14:47 pm
Finally got round to sorting out my off side flexi pipe holder, the old one sheared off with rust -I submitting the temporary fix below as part of my cable-tio-logy:
(https://i.vgy.me/uI2BcX.jpg)

Doing an engine bay check topping up fluids, oil was yet again off the dip stick -I still cant understand why my Mk4 would tell me its low and the Mk5 doesn't? - I spotted these:
(https://i.vgy.me/iss3cm.jpg)

Seems a rodent found some pistachios and decided to carry them all the way up to the valve cover to dine, hope they didn't try cable insulation for desert:
(https://i.vgy.me/QFIaZe.jpg)
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: terrier on July 29, 2020, 07:06:31 pm
"P" clips are ideal for the brake lines :happy2:
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 31, 2020, 10:47:41 pm
"P" clips are ideal for the brake lines :happy2:

good suggestion - even more annoying is there are about 6 of those sat in my bit pile... I was just thinking temporary fix, and find a replacement bracket, forgot to look for one for 2 scrap yard trips.

Bit of an odd day, 2 bits for the Golf showed up at the same time, but they both have problems-
I spotted a Wagner clone intercooler on Aliexpress for a very cheap price, took 3 months to get to me only for it to be damaged in transit:
(https://i.vgy.me/BFO8ie.jpg)
(https://i.vgy.me/oVVOHy.jpg)
(https://i.vgy.me/6F8bKu.jpg)
I have gone back to the seller asking for some money back, don't want to wait another 3 months for replacement, it seems to be Wagner end tanks with divider on the inlet, the only departure is a thicker core size.

And to recapturing my youth - my stealth sub enclosure arrived, to fit a 10" sub - I have had the sub and amp for about 4 years, never got round to installing it in my old Mk4, so kind-of keen to get into the Mk5.
I trial fitted it and it didn't seem to sit right, but ploughed on regardless.
Fitting it highlighted something has gone wrong during the build - maybe warped from heat:
(https://i.vgy.me/j8yZV8.jpg)
(https://i.vgy.me/lAAJHk.jpg)
Too much space under the parcel shelf and it wobbles, I have gone back to the seller and see what he says.

Weather was good, so to cheer myself and keep the amp install rolling, I built my 0 awg power and earth cables:
for big cables a soldering iron wont cut it - blow torch for the win
(https://i.vgy.me/8ZJffu.jpg)
The terminals had hole in the end, the foil blocks that off and the solder got cut into short lengths - the terminal ends up being a crucible
(https://i.vgy.me/IE3EXe.jpg)
Once the solder is melted you just shove the cable in
(https://i.vgy.me/ihd7Rg.jpg)

Previously I had added the signal and RCA, installed the earth to day, all that's left to get the amp up and running is to run the power from the battery and I missed a detail in the instructions, I need a 1 to 2 RCA to allow the amp to be bridged... I already ran a 1 to 1 and cut my hands to ribbons, not looking forward to doing that all again!
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on August 01, 2020, 08:46:09 pm
Got busy with the Amp power cable from the battery, battery out, no wire coat hanger to hand - so used brake pipe and it threaded through the big cable gland:
(https://i.vgy.me/o9oU3h.jpg)
I used OEM busbar/fuse, the width of opening was 6mm narrower than the terminal, so I filed it down to fit.

Earth in the boot, I located it under the middle hinge, just Dremmelled the paint off and used a self tapper -if it comes loose I know I can replace this with a nut and bolt:
(https://i.vgy.me/Epdhig.jpg)
Till I get the new RCA, I have changed the speaker cable to non-bridged - after adjusting the sensitivity to get rid of the doof-doofs it sounds good with 110 watts - 360 bridged will be interesting.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on August 05, 2020, 07:22:09 pm
Well its good news on the sub enclosure, it was all down to my own ineptitude!
I wasn't sliding it into position properly - top in first under the parcel shelf and then the bottom rotates into the space and it slots home as it should:
(https://i.vgy.me/PVZeNG.jpg)

Intercooler - Claim for damage was accepted and got some money back.
It must have had a really hard knock as hammering the dented inlet and outlet took some effort.
End result on the inlet is still slightly out of round - wondering if I should knife edge the internal divider:
(https://i.vgy.me/mgDak5.jpg)
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: Octoparrot on August 05, 2020, 10:45:02 pm
I wouldn't want to risk getting metal shavings into the intercooler.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on August 09, 2020, 09:58:04 pm
I wouldn't want to risk getting metal shavings into the intercooler.

I would agree - but the hammering and some strategic filling to smooth out the lip has already created chunks of alloy, damage or not I was going to rinse it out several times any way, and I could lean it upwards so all the fillings fall straight out.

Yesterday I installed the 2 to 1 RCA, as this is it I tidied the cabling, cable ties and gaff tape, trigger cable got shortened and everything re-sorted to reduce crossovers:
(https://i.vgy.me/cMFsYL.jpg)
So the finalised Amp install:
(https://i.vgy.me/gyM9Ui.jpg)
Quite pleased with the RCA cable management down the side of the amp, strategic cable ties used to hold it in place and keeps it away from the power leads.

Today I connected up the new RCA to the head, all the cabling was getting to be a nightmare as when I installed it it was in a hurry and wasn't sure what I needed.
Now that I am pretty certain I am done with cabling, I sat down and organised the loom. Should have taken a before picture, it was an explosion of wires...
Decided it need to be grouped into 3 looms, Golf OEM, antenna/signal & a group of USB leads.
Cable ties were used to group each loom, the larger of these got trimmed off as I added Tesa fabric loom tape.
The issue with Android heads is they tend to have items that are USB dongles, if anything goes wrong its head out to get at the dongle - I have already had DAB radio go wrong twice, antenna came loose and USB worked itself loose - since then I taped up the USB so they stay put, but also decided these need to be more accessible:
(https://i.vgy.me/mbqFPU.jpg)
Looped around the shifter are the 3 USB leads - these are going under the centre console, DAB radio will be under the ash tray - accessible once lower side panel is removed (one plastic cover and T20 and I'm in!). The other 2 will go to where the arm rest CD changer is currently.
Head unit connected up:
(https://i.vgy.me/F3jqNc.jpg)

Last thing to do in the boot is take out the Sub, remove the awful T-nuts and fit screwed inserts in their place.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on August 29, 2020, 01:46:34 pm
Frustrating week -
About a month ago the CEL came on, VCDS reported an intermittent issue with charging, this fault has not re-occurred since then. Started looking for a good used alternator, thought I found one on ebay, received it and fitted it... only for it not charge.
Seller was decent, sent me another, unfortunately the packaging was no good and the 2 pin connector on the regulator was smashed off on the replacement.
I swapped the temperamental one for faulty one last weekend, at the same time I caught a few items in the same area -
Temperature sensor in thermostat - if I had known back in October when I did the thermostat, I would have replaced the sensor at the same time - hopefully this fixes my fans being on all the time
Yellow dipstick tube - pure vanity item, my orange dipstick started to fall apart, new replacement stick and tube sourced from TPS months ago. I tried to swap it out before but struggled to get the plastic flange off the stud in the intake manifold... I didn't get anywhere until I worked out the stud the has to come out entirely with a 4mm socket.
New drive belt - the only regular maintenance item I had not done in the engine bay... but fuel filter is still sat patiently waiting
(https://i.vgy.me/nAyZQj.jpg)

After 5 days not being able to use the Golf I got the chance to swap back to my original alternator today.
Not too bad a job, but for people who don't have child sized hands that 8mm nut on the P-clip is the worst part.

Going forward I will monitor the charge situation -
I looked at the 2 alternators I was sent, 1st one looked good, but slip ring badly worn.
Second one, apart from smashed regulator, was covered in oil, the slip ring in really good condition.
When I find a genuine Valeo regulator at a good price I will de-grease and rebuild the second alternator and have it as spare.

Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on September 12, 2020, 04:08:20 pm
MOT looming in a just over a months time, need to start fixing known issues, the plan was to fit all this over this weekend:
(https://i.vgy.me/5OksKR.jpg)
In order:
Rebuild nearside driveshaft
Add front galvanised brake shields
Dog bone bush insert
Fuel filter
Rear wheel bearings - not looking forward to the caliper carrier bolts

I opted to take the messy option of rebuilding the OEM shaft as aftermarket shafts tend to be really heavy.

Met office app promised the weather was to be overcast all day, but no rain - started removing the drive shaft only for it to start raining heavily, then later during the one promised sunny hour it started to sleet!

Ducking in and out I finally got the driveshaft out...then comparing the inner CV's the new one is different to the on the Golf:
(https://i.vgy.me/J3mazM.jpg)
Even if this does fit my current bolts are too long, and the outer bolt was different too.
Pretty much stopping all the front axle work and it has disabled the Golf till I know what is going on

The only work I did continue with was the slash guard on the nearside - my MOT tester has a real hard-on for these, adding observations if they are not present, we all love these faults being added to the MOT record, its simpler to just install them - I managed to find some galvanised ones,  strangely for this car the only issue was the bolts have rusted so much the torx just let go, same for bigger allen head and torx...
Ended up getting all 3 out with a combination of blow torch, penetrant, Dremeled out a slot in the head and then impact driver:
(https://i.vgy.me/mXrVZd.jpg)

And temporary fit of guard with stainless bolts:
(https://i.vgy.me/xA5STB.jpg)

By this time I was pretty pee-peed off, so I have now downed tools and come inside... and I am about to crack open a beer.
I may have a go at some other bits tomorrow...the met office promised it will be lovely!!

Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: terrier on September 12, 2020, 06:04:43 pm
The shields love to rust. My previous mk5 went through 3 sets in 100000 miles This time around Ive painted them with underseal. Also give them a clean with an oily rag every few months,held in place with plastic screws from work (borrowed) :happy2:
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on September 12, 2020, 07:56:57 pm
Yeah - When I got the Golf there was only the crumbling remains of the passenger side left - these are galvanised sheet pressed, their weakness is the cut edge is bare metal, hopefully these should have good life expectancy
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on September 18, 2020, 09:25:21 pm
I was struggling to get the rear carrier bolts off, I invested in some low profile spline sockets and they helped along with taking the spring and shock off giving excellent access - all 4 fought me all the way out:
(https://i.vgy.me/Ey6gsZ.jpg)
Finally progressing, only had to get the angle grinder out for the ARB drop links:
(https://i.vgy.me/mKI3hc.jpg)
The bits I got off:
(https://i.vgy.me/SKQ6Ip.jpg)
before finally getting this out..
(https://i.vgy.me/y1r9YH.jpg)
The MVP for getting the subframe out was the VAG connector remover used to get the level sensor connector off:
(https://i.vgy.me/366Idg.jpg)
Subframe is in mint condition, still has its stickers on!
(https://i.vgy.me/jeT52I.jpg)
I have these to deal with tomorrow - 3 bolts are stuck in the bushes, will see what a bit of heat does. most of the bushes look and feel goosed, suspect they are original ones
(https://i.vgy.me/0a5Z9j.jpg)
I had mixed results with my cheap Aliexpress subframe aligners 2 had bits broken off, the rest were still good, all the aligning bits are still good, still happy with them:
(https://i.vgy.me/NsHP2V.jpg)
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: Stupots on September 19, 2020, 07:57:42 am
Holy hell @LC5F (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=49808) I now understand what "Sea Dweller" really means. The level of rust on your car is extreme!

Replacing any bits with alloy parts?

P.S. I just ordered one of those VWAG Connector Remover tools... good shout!
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on September 19, 2020, 10:53:55 am
Holy hell @LC5F (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=49808) I now understand what "Sea Dweller" really means. The level of rust on your car is extreme!

Replacing any bits with alloy parts?

P.S. I just ordered one of those VWAG Connector Remover tools... good shout!

To be fair I have had this tool for a while, tried it a half heartedly and couldn't get it to work. But this is the first time I got the remover to work - it is definitely something to have in reserve - the level sensor clip is covered by the body of the subframe. Normally if access is good I can undo with finger or carefully with flat blade screwdriver, but I will start using this more

Yes - I have Scirocco hubs to go on and all the PSB bushes
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on September 19, 2020, 05:44:55 pm
Plan today was strip and clean the subframe, looking at it in the daylight made me realise the condition is too far gone for me to clean up, likely to take days of wire brushing with poor result...
(https://i.vgy.me/hUaI0M.jpg)
(https://i.vgy.me/sniC2W.jpg)
(https://i.vgy.me/K32b3p.jpg)
So, I have opted to buy a good second hand rear axle from down south outside the rust zone, looks to be in a much better condition to rebuild.
In the meantime I will clean up 4 of the arms ready to go on. Upper arm crust was this:
(https://i.vgy.me/6bfDpb.jpg)
Most of that flaked off with hammer and then wire brushed on an angle grinder to near bare metal. Next I pushed out the old bushes, only one came out clean, most left their metal casing - I had to file a groove and hammer/lever it out:
(https://i.vgy.me/o7HNrs.jpg)
Also got round to installing the vice I got 7 months ago into my home built bench, this allowed me to remove the old bearings from the Scirocco hubs - I burnt out the bush centre, need to hacksaw through the remains of the bush:
(https://i.vgy.me/UtIVRF.jpg)
Scirocco alloy Vs Golf cast iron hubs:
(https://i.vgy.me/FhWcjc.jpg)
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: maxamplitude10 on September 20, 2020, 02:02:59 pm
How is it so rusty must have been parked in the sea for most of its life? That is an unseen amount of rust on a GTI....

Good Luck

Max
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on September 20, 2020, 07:08:27 pm
How is it so rusty must have been parked in the sea for most of its life? That is an unseen amount of rust on a GTI....

Good Luck

Max

Thanks - Don't know where its been, except I got it in Aberdeen and was parked near the docks.
It was an Edinburgh registered car, so it has done a big loop back.
I need to dig out my registration and look through online MOT history for clues to where it spent its life.
All I can think is it may have been somewhere rural with Cow slurry - the ammonia really helps rust

So today I worked out I messed up the lower control arms for the PSB bushes - pretty random that they say you need to burn out the bush and retain the OEM metal outer for the PSB ones to slip into, I seem to recall Superpro come with the casing, but the big price - mine were rusted and splitting and I removed them yesterday.
Typically I found this out after wire brushing and rust converted both arms! - hopefully the ones on the axle coming up from London will be in better shape.

Upper control arms wire brushed back to metal and treated with rust converter, next step is some smoothrite and fit the bushes.
(https://i.vgy.me/5B4pGc.jpg)

Scirocco hubs got a scrub down with wire brush and the remains of the control arm bush pushed out and PSB installed.

Don't think I mentioned the state of the exposed floor around and above the subframe:
(https://i.vgy.me/qexwes.jpg)

After a reasonably thorough scrub with wire wheels I got it back to this:
(https://i.vgy.me/glm4TF.jpg)

The dust was terrible, should have put on a respirator to go with my safety squints behind glasses - I use the boot carpet from a Mk3 for rolling around on the ground, outline can be seen below:
(https://i.vgy.me/wL36ah.jpg)

Now treated with rust converter, not sure if I should stone chip or only paint with smoothrite:
(https://i.vgy.me/n87jQu.jpg)
 



Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: Deano45 on September 22, 2020, 11:41:30 am
Top work ,,, great progress on this restoration so far and some great upgrades ,,, :smiley:
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on September 26, 2020, 10:49:26 pm
Top work ,,, great progress on this restoration so far and some great upgrades ,,, :smiley:

Thanks fella - I am more going for future proofing for a reliable good handling daily.
If it was full blown resto, despite the good spec I don't think I would have chosen this Golf, plus I would be powder coating everything.

Wednesday -
I got some bargain priced Passat front hubs, amazing packaging and DHL'd next working day all for £14 a side
They wont make it onto the Golf for a while. They came complete with discs, bearings, shields etc.
Getting the bearings off was easy once I worked out how to hold them rigid off a car:
(https://i.vgy.me/jFM6qM.jpg)
They got a pretty good scrub down, but to give the cleaning a leg up, I decided to be naughty:
(https://i.vgy.me/Y3wa1U.jpg)
It was only a 30 minute wash cycle, couldn't risk a longer one!

Friday -
The Axle turned up on, the good news is this one has considerably more paint still on it:
(https://i.vgy.me/Ys1jii.jpg)
Stripped it down to the usual 2 control arms - everything was in much better shape, even the ARB bolts came out. it took a 1/4 of the time my old one took!
Night time, I installed bushes into the upper control arms

Saturday -
First task was painting the boot floor, I opted for stonechip, 1.5 cans later I got this:
(https://i.vgy.me/UCIwqb.jpg)
Not perfect, but it should help.

Second task was getting the last 2 control arm bolts out, they gave in to lots of heat, that left me with a bare subframe that I wire wheeled the crusty areas and then rust converted:
(https://i.vgy.me/iktRxz.jpg)
The milestone here is I have reached bottom on the axle rebuild, apart from cleaning up parts it now all going back on.

Rest of the day spent stripping out bushes and cleaning up parts-
I think I blew out the seal on my cheap ebay press trying to take out the 2nd trailing arm bushes - metal inner pushed out, but I had to cut the alloy outer case to push it out.
The Lower control arms I cleaned up by accident are noticeably lighter than the new ones, I didn't realised how pitted they are until I noticed the PN on the new ones. Wire wheeled, rust converted & smooth Hammerite'd:
(https://i.vgy.me/xOtEJy.jpg)
Mid control arm:
(https://i.vgy.me/ebBweN.jpg)

For a break, I had a go at swapping the fuel filter - I was not successful.
On the rear of the filter - the Blue clip hose undidid, but black clip was previously out is now jammed in and refused to budge despite several doses of brake cleaner and penetrating fluid...

Everything has now had a good lick of paint, hopefully tomorrow it will just be some touch ups, pushing bushes into arms and then start re-assembly.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: kodirl on September 27, 2020, 06:40:00 am
Top work ,,, great progress on this restoration so far and some great upgrades ,,, :smiley:

Thanks fella - I am more going for future proofing for a reliable good handling daily.
If it was full blown resto, despite the good spec I don't think I would have chosen this Golf, plus I would be powder coating everything.

Wednesday -
I got some bargain priced Passat front hubs, amazing packaging and DHL'd next working day all for £14 a side
They wont make it onto the Golf for a while. They came complete with discs, bearings, shields etc.
Getting the bearings off was easy once I worked out how to hold them rigid off a car:
(https://i.vgy.me/jFM6qM.jpg)
They got a pretty good scrub down, but to give the cleaning a leg up, I decided to be naughty:
(https://i.vgy.me/Y3wa1U.jpg)
It was only a 30 minute wash cycle, couldn't risk a longer one!

Friday -
The Axle turned up on, the good news is this one has considerably more paint still on it:
(https://i.vgy.me/Ys1jii.jpg)
Stripped it down to the usual 2 control arms - everything was in much better shape, even the ARB bolts came out. it took a 1/4 of the time my old one took!
Night time, I installed bushes into the upper control arms

Saturday -
First task was painting the boot floor, I opted for stonechip, 1.5 cans later I got this:
(https://i.vgy.me/UCIwqb.jpg)
Not perfect, but it should help.

Second task was getting the last 2 control arm bolts out, they gave in to lots of heat, that left me with a bare subframe that I wire wheeled the crusty areas and then rust converted:
(https://i.vgy.me/iktRxz.jpg)
The milestone here is I have reached bottom on the axle rebuild, apart from cleaning up parts it now all going back on.

Rest of the day spent stripping out bushes and cleaning up parts-
I think I blew out the seal on my cheap ebay press trying to take out the 2nd trailing arm bushes - metal inner pushed out, but I had to cut the alloy outer case to push it out.
The Lower control arms I cleaned up by accident are noticeably lighter than the new ones, I didn't realised how pitted they are until I noticed the PN on the new ones. Wire wheeled, rust converted & smooth Hammerite'd:
(https://i.vgy.me/xOtEJy.jpg)
Mid control arm:
(https://i.vgy.me/ebBweN.jpg)

For a break, I had a go at swapping the fuel filter - I was not successful.
On the rear of the filter - the Blue clip hose undidid, but black clip was previously out is now jammed in and refused to budge despite several doses of brake cleaner and penetrating fluid...

Everything has now had a good lick of paint, hopefully tomorrow it will just be some touch ups, pushing bushes into arms and then start re-assembly.
Fantastic work. Great detail. Wish I had the patience and know how to do these kind of jobs myself. Keep up the good work

Sent from my Mi A2 using Tapatalk

Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on September 27, 2020, 08:23:49 pm
@kodirl (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=8057) - Thanks for the kind words

Got the bushes installed:
(https://i.vgy.me/yo9zGg.jpg)
but managed to misunderstand the ones on the lower control arm and had to swap them over

Started going through the big bag of bolts, marking depths of bushes to strategically copper grease them:
(https://i.vgy.me/gmcWJm.jpg)
(https://i.vgy.me/EtyofW.jpg)
(https://i.vgy.me/3rCnfU.jpg)
This stops getting grease under the nut and making it easy to over torque the bolts - hopefully this will keep the cam bolts free to move. thinking about it I could seal the groove in the bolt to reduce moisture sitting within the bush.

Old leveller frame has rusted so badly it was close to tin foil thickness, plue and the arm was stretched - it wasn't genuine - so quite happy to install a cheap headlight leveler but using stainless rivnuts and bolts + thread lock to seal everything:
(https://i.vgy.me/fY6ziH.jpg)

Finally after last touch ups the subframe was ready to go back in:
(https://i.vgy.me/dOs0RG.jpg)
This how it looks installed:
(https://i.vgy.me/wXgOL8.jpg)
Current state is everything on, except the mid-control arm, springs, bearings, brakes etc. They all need to be torqued up - So far I have not bothered making any alignment - think I will just put them in the middle for now - still likely to drive like a banana:
(https://i.vgy.me/05Jloa.jpg)



Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on September 28, 2020, 06:38:47 pm
Public holiday for me today, so its the final push to get the Golf back on 4 wheels

Torqued up all the assembled bolts, started adding the Scirocco back plates and then the new bearings, seems the brake discs fouling the aluminium back plates, these got adjusted with hammer so they fit all round.

I had noticed the right rear caliper hard pipe between flexi and caliper was corroded -MOT fail - and the same pipe on other side was badly made when the garage fitted a new caliper after last years MOT.
I decided to swap both calipers over for the ones I rebuilt but paint was a disaster, this was along with the last Hel stainless brake lines.
(https://i.vgy.me/2wc2ux.jpg)
Last steps were installing the mid control arm, and re-mounted the back box on the exhaust - surprisingly easy, hardest part was undoing the clamp.
Brakes bled, putting the wheels back on and off the axle stands. After a quick drive round the block I found the superpro engine mount had introduced a vibration in the dash at low speeds, and can feel the rear wheels fighting each other -alignment booked for Wednesday.

Along with them being lighter and ABS sensors really easy to remove - the Scirocco hubs do increase track and push the wheels out - Look no spacers:
(https://i.vgy.me/8SNqpR.jpg)

Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: maxamplitude10 on October 08, 2020, 06:19:40 pm
Rear stance looks really nice with the scirocco hubs i'm tempted to carry out the same on mine...:-0

 :happy2:
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on October 16, 2020, 02:05:23 pm
Rear stance looks really nice with the scirocco hubs i'm tempted to carry out the same on mine...:-0

 :happy2:

Cheers - there is a bit of light rubbing under hard cornering, hoping ARB's will reduce that. Also I have not tried it with passengers in the back... may need to lift it a bit and also do some arch rolling.

So finally set a date for the MOT, in town garages are still swamped by MOT backlog they couldn't give me a date till next month, I ended up having to go out of town.
Initial test it failed on headlight adjustment - 1cm too low! - after some digital adjustment, it passed with no advisories.

The weekend before the test I had a final mechanical fix to do.
Somehow, the hand brake on the rear calipers I had rebuilt was not working, I had to swap back to the original calipers for the MOT.
Both old calipers got the pistons pushed out and a good clean out and re-grease, the older caliper got new seal and dust boot.
My rear axle is the gift that keeps on giving - it came with the smaller caliper type, but they had good flexi to caliper hard lines, these got fitted. Need to list the left over good bits to get some money back.
Thanks to the way the Mk5 runs its brake lines to the rear its really easy to bleed, both sides swapped and bled within an hour.

What I had done wrong on both calipers was the spring clip that holds the internal spring loaded handbrake mechanism in place was not seated properly -lets just say its easier to take out than put back in!
I couldn't tell as I had bolted the handbrake arm in place - Now that I know, next time I will check that its seated properly before the arm gets added.

Seeing as they were both apart, it seemed rude not to strip them fully back down and deal with the awful -supposed to be Red - orange Halfords caliper paint.
With Black Golf R calipers up front - I currently have a collar does not match the cuff situation, so off to powder coating with this lot:
(https://i.vgy.me/RLsD8n.jpg)

Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: terrier on October 16, 2020, 06:19:22 pm
Worth paying for a pre MOT check to avoid failure(s)  I pay £20 plus the MOT fee of £50. Both Mk5s are 12/13 yrs old with 6 figure mileage :driver:
 Also having problems with my handbrake. In my case the pivot bush for the handle has come adrift and started to chew the hb housing
 Replacement is 40 plus 2 new cables at 38 At least its an easy job and ill do it at work while getting paid :jumpmove: :jumpmove:
  Shame about the paint. Reminds me of an old pink :grin: astra i had
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on October 16, 2020, 08:40:57 pm
I remember when they started logging faults with MOT's, a few VW guys were up in arms about them being recorded and even more annoyed that they were accessible by anyone - not sure what they were trying to hide!
Personally I'm not fussed, advisories were a good idea, its a lead for potential for work at the garage or a heads up for DIY mechanic and with it being online, no issue of loosing the certificate like back in the day - it's a transparent process and this time the fault was fixed the same day.

Where are you in the world that an MOT is still £50?
Full price its £29.50 for me in Edinburgh - but being a repeat user got a voucher taking it down to £25
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: terrier on October 16, 2020, 10:28:10 pm
Where are you in the world that an MOT is still £50?  Local city council
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: shannon-ob on October 17, 2020, 07:28:37 pm
Some good progress made bud!

Sadly, you’re going to struggle to roll rear arches... there’s nothing really to roll!

For anyone interested, the Passat/scirocco hubs widen the track an extra 12mm per side.


Sent from my iPhone using Tapatalk
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on October 18, 2020, 09:54:49 pm
Some good progress made bud!
Sadly, you’re going to struggle to roll rear arches... there’s nothing really to roll!
For anyone interested, the Passat/scirocco hubs widen the track an extra 12mm per side.

Thanks Fella -
I was meaning to discreetly pull the rear lip out a bit with an arch roller to help clearance, but may look odd.
I thought Rocco hubs added 10mm a side but may have misread or got mixed up with 10mm spacers that I was initially looking at - from my research should have fitted without this issue, but I wanted something more discrete and OEM +reduced unsprung weight is a bonus too.
It seems the extra 2mm must causing the rubbing, its not constant or prolonged so it's not a big issue for me just now.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on November 14, 2020, 02:55:35 pm
I got the calipers back from powder coating:
(https://i.vgy.me/gdpcZN.jpg)
Sadly they are going to need a lot of tidying up, lots of coating on matting surfaces and they didnt block up the cylinder while blasting so I need to hone the bore again!

Did a trip to my favourite scrap yard, I was looking for Aero parts for underside but every car was up on stacked wheels destroying the parts I was looking for.
Shifted the search to MFSW, I thought I had looked at every Mk5 & Passat, I was about to head off when I spotted a black one.
It had the switches, weirdly the airbag had already been removed.. why leave the valuable switches?
Took the switches and the module out in one piece, cost at my yard for one set of switches a bargain £6
(https://i.vgy.me/KrQVpf.jpg)
Cheeky celebratory Burger King on the way home - no que at the drive through - Great success!
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on November 14, 2020, 05:39:12 pm
I was too keen to wait till daylight...head torch + I was careful & didnt disconnect battery...fitted:
(https://i.vgy.me/9BU7GR.jpg)
Worked straight away thanks to mine being DSG
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on December 11, 2020, 03:56:09 pm
Yesterday I finished work for the year and has freed me up to get a chance to do stuff with the Golf.

First task was to get rid of all the old parts I had accumulated- The majority of the stuff was a pile of rusty Mk5 parts, Mk4 hatch and a clothes airer in the front garden:
(https://i.vgy.me/BdEEcU.jpg)

Loaded up I have some nice tuck:
(https://i.vgy.me/9HvvoO.jpg)

Took that lot to be weighted in, weigh bridge on entry 1630, emptied 1430kg - thats with fuel tank hovering around the red line - operator said it was a heavy car! 
So for 200kg of mixed steel and cast iron I got £25, a little bit better than £0 if I took it to the council waste centre.

One thing I had been reading about right from start with the Mk5 was OEM aero upgrades, there is a great thread on here.
Between Ebay & TPS I got all these and the hardware to fit:
(https://i.vgy.me/qiOo6j.jpg)

Engine undertray was from TPS, I am friendly with the guys there and they give me discount, pattern copies on ebay without the vents are £50, I was really surprised when a genuine one was £50 plus vat. If I remember its a TT undertray, difference from shorty one is:
(https://i.vgy.me/NPWuET.jpg)

Should speed up engine warm up, keep bay cleaner and reduce drag - from initial short drive it is noticeably quieter.
I also fitted the pyramid strips too, very easy to install.
The last piece to fit is the curvy part that smoothes out air after the fuel tank - it bolts onto the subframe, one side needs drilling to install a captive riv-nut stud and a bracket installed on the other side - going to wait till the spring to do this part.
Last thing I did to the Golf was an oil service. So the nagging "service now" chime is silenced for another year.


Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: fakie1977 on December 11, 2020, 09:18:40 pm
Yesterday I finished work for the year and has freed me up to get a chance to do stuff with the Golf.

First task was to get rid of all the old parts I had accumulated- The majority of the stuff was a pile of rusty Mk5 parts, Mk4 hatch and a clothes airer in the front garden:
(https://i.vgy.me/BdEEcU.jpg)

Loaded up I have some nice tuck:
(https://i.vgy.me/9HvvoO.jpg)

Took that lot to be weighted in, weigh bridge on entry 1630, emptied 1430kg - thats with fuel tank hovering around the red line - operator said it was a heavy car! 
So for 200kg of mixed steel and cast iron I got £25, a little bit better than £0 if I took it to the council waste centre.

One thing I had been reading about right from start with the Mk5 was OEM aero upgrades, there is a great thread on here.
Between Ebay & TPS I got all these and the hardware to fit:
(https://i.vgy.me/qiOo6j.jpg)

Engine undertray was from TPS, I am friendly with the guys there and they give me discount, pattern copies on ebay without the vents are £50, I was really surprised when a genuine one was £50 plus vat. If I remember its a TT undertray, difference from shorty one is:
(https://i.vgy.me/NPWuET.jpg)

Should speed up engine warm up, keep bay cleaner and reduce drag - from initial short drive it is noticeably quieter.
I also fitted the pyramid strips too, very easy to install.
The last piece to fit is the curvy part that smoothes out air after the fuel tank - it bolts onto the subframe, one side needs drilling to install a captive riv-nut stud and a bracket installed on the other side - going to wait till the spring to do this part.
Last thing I did to the Golf was an oil service. So the nagging "service now" chime is silenced for another year.
What’s the part numbers for those parts?


Sent from my iPhone using Tapatalk
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on December 12, 2020, 01:26:16 pm
What’s the part numbers for those parts?

Here you go-

Engine undertray:
1K0 825 237 P
3x 1K0 825 951 - you re-use the original 8 at the front & these 3 bolt into subframe

Pyramid parts are:
1K0825002B
1K0825001B
10x N 103 546 02
4x N 909 591 01

Fuel tank smoother-outer
1K0501713E
1x 1K0 501 682
1x N 905 483 05
1x N 901 838 02
1x N 910 011 01 -this is the riv-nut stud, apparently later rear axles have this stud built in

Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on January 30, 2021, 10:28:36 pm
Been a while since any update-
I finally got my front bearings to go into my passat hubs - suspect its going to be a while before weather is favourable - also a 3D printed walnut blasting vacuum thingy, going to get a cheap top feed blaster gun and add a length of metal fuel line to get into the cylinder head:
(https://i.vgy.me/XIMvCN.jpg)

Christmas present to myself was some chineseum carbon DSG extenders:
(https://i.vgy.me/oMWRbE.jpg)

And fitted:
(https://i.vgy.me/qpNMX7.jpg)
They are real carbon with a good gel coat, they seem to be a vacuum formed hollow shell, but couldn't see a air hole -unless its hidden under the double sided tape - really pleased they have no random company logo, only the +&-
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: BillyTahir on March 22, 2021, 08:57:24 pm
Public holiday for me today, so its the final push to get the Golf back on 4 wheels

Torqued up all the assembled bolts, started adding the Scirocco back plates and then the new bearings, seems the brake discs fouling the aluminium back plates, these got adjusted with hammer so they fit all round.

I had noticed the right rear caliper hard pipe between flexi and caliper was corroded -MOT fail - and the same pipe on other side was badly made when the garage fitted a new caliper after last years MOT.
I decided to swap both calipers over for the ones I rebuilt but paint was a disaster, this was along with the last Hel stainless brake lines.
(https://i.vgy.me/2wc2ux.jpg)
Last steps were installing the mid control arm, and re-mounted the back box on the exhaust - surprisingly easy, hardest part was undoing the clamp.
Brakes bled, putting the wheels back on and off the axle stands. After a quick drive round the block I found the superpro engine mount had introduced a vibration in the dash at low speeds, and can feel the rear wheels fighting each other -alignment booked for Wednesday.

Along with them being lighter and ABS sensors really easy to remove - the Scirocco hubs do increase track and push the wheels out - Look no spacers:
(https://i.vgy.me/8SNqpR.jpg)
Done good job there mate looks nice with scirocco, but im abit 50/50 with poly bushing my rear dont fancy the vibration haha


Sent from my iPhone using Tapatalk
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: Jons1001 on March 22, 2021, 09:22:44 pm
Hi where did you get the shifters from please? Have you got a link? I've currently got the metal ones but yours look much nicer.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on March 22, 2021, 10:13:13 pm
Hi where did you get the shifters from please? Have you got a link? I've currently got the metal ones but yours look much nicer.

Thanks fella - I got them from aliexpress: https://www.aliexpress.com/item/1005001874692654.html?spm=a2g0s.9042311.0.0.6e544c4dMoUDZr (https://www.aliexpress.com/item/1005001874692654.html?spm=a2g0s.9042311.0.0.6e544c4dMoUDZr)
Delivery was quick & sticky pads have held.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: shannon-ob on April 03, 2021, 02:08:28 pm
Some good progress made bud!
Sadly, you’re going to struggle to roll rear arches... there’s nothing really to roll!
For anyone interested, the Passat/scirocco hubs widen the track an extra 12mm per side.

Thanks Fella -
I was meaning to discreetly pull the rear lip out a bit with an arch roller to help clearance, but may look odd.
I thought Rocco hubs added 10mm a side but may have misread or got mixed up with 10mm spacers that I was initially looking at - from my research should have fitted without this issue, but I wanted something more discrete and OEM +reduced unsprung weight is a bonus too.
It seems the extra 2mm must causing the rubbing, its not constant or prolonged so it's not a big issue for me just now.

Sadly you'll still struggle.

I'm just going to fit a BTCC arch kit, although my car is a track car!
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on April 03, 2021, 02:17:07 pm
@shannon-ob (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=41156) Thanks for confirming - my rears have clearanced themselves - front still rubs, but only on hard cornering - so still hopeful for some H&R's to sort out body roll - or just lift the coils up.
How much body work do you need to chop out for BTCC arches?
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: shannon-ob on April 03, 2021, 02:22:19 pm
@LC5F (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=49808) I did think about letting mine clearance themselves when I had the 8J wheels, but when I went to 9J there would be no chance. I'm surprised that your fronts rub...
I'm not entirely sure until I buy the kit. Hopefully enough that I won't get any more rubbing issues.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on April 03, 2021, 02:50:50 pm
@LC5F (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=49808) I'm surprised that your fronts rub...
its the R32 TT alloy arms pushing the wheel out further.
Good luck with the bodywork on yours
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: shannon-ob on April 03, 2021, 03:07:04 pm
Ahh are they different to S3 arms?
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: colesey on April 03, 2021, 07:45:42 pm
Ahh are they different to S3 arms?

Yep, wider track.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: shannon-ob on April 03, 2021, 09:06:32 pm
Ahh are they different to S3 arms?

Yep, wider track.
Ohhh I never knew that! How much by do you know?


Sent from my iPhone using Tapatalk
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: colesey on April 04, 2021, 07:45:13 am
From memory its @1/2” per side.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: shannon-ob on April 04, 2021, 09:50:40 am
Oh blimey! Never new that! Guessing it’ll add more negative camber too?


Sent from my iPhone using Tapatalk
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: colesey on April 04, 2021, 09:55:57 am
Extra length plus adjustable balljoints so, yep, extra camber.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: shannon-ob on April 04, 2021, 09:57:33 am
Thanks for your help I’ll stop jamming up this thread I may have to invest in a pair. Could someone pm me part numbers?


Sent from my iPhone using Tapatalk
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: colesey on April 04, 2021, 10:23:19 am
If you do some searching on this site, there’s parts numbers in one thread.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on April 04, 2021, 12:05:40 pm
You guys have been busy! - No worries, the ones I got are 8J0407151D, only £35 a side so its not an expensive upgrade:
(https://i.vgy.me/n8jrYr.jpg)
(https://i.vgy.me/fxvKNy.jpg)

I went with Lemforder TT ball joints, the 3 bolt cage connecting joint to control arm seems to be surprisingly expensive and is not provided with ball joint. Ended up with anti loosening high tensile nuts and bolts
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: fakie1977 on April 13, 2021, 08:30:37 am
You guys have been busy! - No worries, the ones I got are 8J0407151D, only £35 a side so its not an expensive upgrade:
(https://i.vgy.me/n8jrYr.jpg)
(https://i.vgy.me/fxvKNy.jpg)

I went with Lemforder TT ball joints, the 3 bolt cage connecting joint to control arm seems to be surprisingly expensive and is not provided with ball joint. Ended up with anti loosening high tensile nuts and bolts
Do you have part number/links to the ball joints and nuts & bolts? Thanks


Sent from my iPhone using Tapatalk
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on April 13, 2021, 07:17:23 pm
Do you have part number/links to the ball joints and nuts & bolts? Thanks

I just looked up a M2 Audi TT R32 on ECP and it gave me 617443285 & 617443295
Nuts, bolts & washers I sourced from ebay, items I got are no longer listed - they need to be high tensile 10.9 M10 40mm (40 is a touch too long 35mm should be about right) with high tensile (if possible nyloc) nuts to suit.

In other random news, tonight I spotted this fubar'd Maserati, it makes the rust on the underside of my golf seem amateurish!
The good:
(https://i.vgy.me/X3UAlZ.jpg)
The bad:
(https://i.vgy.me/ntrnrV.jpg)
And the ugly:
(https://i.vgy.me/yT1cBy.jpg)
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: fakie1977 on April 13, 2021, 07:58:11 pm
Do you have part number/links to the ball joints and nuts & bolts? Thanks

I just looked up a M2 Audi TT R32 on ECP and it gave me 617443285 & 617443295
Nuts, bolts & washers I sourced from ebay, items I got are no longer listed - they need to be high tensile 10.9 M10 40mm (40 is a touch too long 35mm should be about right) with high tensile (if possible nyloc) nuts to suit.

In other random news, tonight I spotted this fubar'd Maserati, it makes the rust on the underside of my golf seem amateurish!
The good:
(https://i.vgy.me/X3UAlZ.jpg)
The bad:
(https://i.vgy.me/ntrnrV.jpg)
And the ugly:
(https://i.vgy.me/yT1cBy.jpg)
Thanks. I assume carparts4less is exactly the same? With current sale it’s about half price compared to ECP.


Sent from my iPhone using Tapatalk
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on April 13, 2021, 08:44:50 pm
I understand they are the same organisation - but ECP tend to have a discount on their front page or you can try either or both the Pouch and Honey browser add ons - when activated they automatically try multiple discount codes searching for cheapest - for me I have a euro's 1.5 miles away I usually click and collect so I can check the parts...something you cant do with CP4L
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 04, 2021, 07:42:34 pm
Long overdue update -
Added an amp to power the Pioneer components in the front doors - just an old one I had sitting in the garage.
(https://i.vgy.me/1ib9JK.jpg)
had to replace the fuse block and get a splitter for the earths, need to get some decent 90 elbows to pull the cables out of the feet zone!  This is wired using the JL highpass filter so sub and components are not treading on each other - midrange is really impressive.

Other things going on -
The annoying zombie car effect returned, thought the new canbus fixed it - where the Golf plays dead and then comes back to life - I think I have narrowed it down to the terminal 15 relay going bad... well banging the bottom of the dash or opening the door or bonnet seems to get it going again - should get a new relay on Tuesday.
I kept getting an intermittent error 012599 - this seems to have been solved by replacing the MAP sensor, huge difference in boost and general smoothness.

I tried to replace my fuel filter 1.5 years ago -at the time I was stopped by a jammed clip - finally remembered to get a new line from the tank at TPS yesterday.
Taking the old filter out was the first task, the cage retaining screw was fubar by rust - no surprise on this Golf
A quick grind with a Dremmel revealed the cross head, but there wasn't enough to undo - ended up drilling the head off and gripping the stub with vice grips that was replaced by an Audi stainless T20:
(https://i.vgy.me/OdDjdx.jpg)
with filter loose I jumped inside and undid the connection on the tank and pulled the old pipe and filter out:
(https://i.vgy.me/cFd0Hx.jpg)
Date on the old filter was 2013 so possibly I thought there was a lot more room on top of the tank - only after adding a long cable tie was I able to pull the pipe down to the filter.
New filter has made low speed throttle response better, further enhancing the smoothness of the new MAP. tipping out the inlet side there was a distinct brown colour - just a relief to finally get it swapped out

Finally got a sport cat downpipe from Pipeworx - looks really well made and is 2 piece - should make install easier.
Unfortunately it came with swage reduced pipe to connect onto a standard system - got to chop 75mm off
Worse still - measuring from the hanger to the installed Cobra cat back system, once it is chopped back it will be 150mm too short... oh well, more time more expense!


Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 11, 2021, 07:14:36 pm
Small update -
Occasionally I find my number plate lights flickering, I had fitted better quality LED bulbs... so not ideal
Hopefully an OEM solution in Mk7 LED number plate lights will work better:
(https://i.vgy.me/Ofm3Gp.jpg)

I did get a quote from TPS for these, they were double the price excluding VAT of these on ebay.

Fitting turned into a saga - I had not noticed the light had a spring clip, ended up managing to push the back plate into the bumper and ended up loosing one of the lights inside the bumper!

Ended up bumper off - at least I got to mount the rear view parking camera and run the cables into the boot.
Kind of discrete and the top of the 6 hides it, or I could remount the plate lower:
(https://i.vgy.me/d6SEBQ.jpg)
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: pandaman on July 11, 2021, 10:41:24 pm
Small update -
Occasionally I find my number plate lights flickering, I had fitted better quality LED bulbs... so not ideal
Hopefully an OEM solution in Mk7 LED number plate lights will work better:
(https://i.vgy.me/Ofm3Gp.jpg)

I did get a quote from TPS for these, they were double the price excluding VAT of these on ebay.

Fitting turned into a saga - I had not noticed the light had a spring clip, ended up managing to push the back plate into the bumper and ended up loosing one of the lights inside the bumper!

Ended up bumper off - at least I got to mount the rear view parking camera and run the cables into the boot.
Kind of discrete and the top of the 6 hides it, or I could remount the plate lower:
(https://i.vgy.me/d6SEBQ.jpg)

Got some of these (off ebay as well) last year, they work but still very occasionally through up the warning light on the dash. I had LED bulbs before that, one wasn't working for an MOT and the guy changed it for a normal bulb and still the warning light was on. So I'm wondering if there's something else wrong causing the warning light occasionally, hopefully something vcds can solve. Please let me know if this throughs up any warning lights at all, cheers.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 13, 2021, 10:30:44 pm
@pandaman (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=16980) - Thanks, I will keep an eye out for this issue
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 17, 2021, 06:29:21 pm
@pandaman (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=16980) - Thanks, I will keep an eye out for this issue

Yes - now experienced this twice - hopefully it's just the hot weather
Golf seems to do a few odd things in the heat, currently have no cooling AC has been low for a while waiting for condenser and intercooler to be replaced.
Could the LED numberplate lights be coded in or out in VCDS?

Update - Brown Santa came earlier this week with this from DPM... actually they were more traditional Red as they were parcelforce:
(https://i.vgy.me/1bl6T7.jpg)

Got to play today, nice having good weather to work on the Golf.
I was dreading doing the downpipe, night before with the engine warm I whipped off the intake emptied half a can of penetration fluid onto the studs, thought it was going to ignite it was smoking so much.

All 4 nuts came off - I had new studs, but looking at the space available and the tools I have I couldn't find any decent way to remove them - so undecided not to push my luck and struck with the old studs.
Pipeworx sport cat downpipe being prepared:
(https://i.vgy.me/zn1JYa.jpg)
And installed:
(https://i.vgy.me/oTN3Go.jpg)
Ended up getting a slip extension pipe that I cut to size:
(https://i.vgy.me/2psT3z.jpg)

Strangely all the nuts on the 2 cross braces under the exhaust came off without any problems - unusual for this car!

Old clamps - think they are the ones supplied by Cobra - were a PITA to remove and look like something Victorian compared to the Miklor W4s:
(https://i.vgy.me/lV6vBh.jpg)
got the rear ARB installed and also added the last bit of Aero - panel after the tank blocking off the sub frame:
(https://i.vgy.me/KrsF6L.jpg)

Tomorrow is swapping out the intercooler, filled it with water 4 times and emptied it out - then filled it a 5th time to test for leaks and left it overnight - still full in the morning.




Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: pandaman on July 17, 2021, 10:09:40 pm
@pandaman (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=16980) - Thanks, I will keep an eye out for this issue

Yes - now experienced this twice - hopefully it's just the hot weather
Golf seems to do a few odd things in the heat, currently have no cooling AC has been low for a while waiting for condenser and intercooler to be replaced.
Could the LED numberplate lights be coded in or out in VCDS?

Well that's a bummer but also rules out something else my end. Dunno if its got anything to do with heat, im pretty sure it was doing it though winter as well.
VCDS seems our best bet, I'll do some googling.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 19, 2021, 01:43:04 pm
Well I changed my mind about what to do next, rather than take on the relatively clean intercooler swap, I decided to get the messy front ARB out the way and then the intercooler.
Dropping the subframe, removing the old ARB, drilling out the captive nuts on the OEM bushes were straight forward -thought I would be done in 1.5 to 2 hours...but didn't budget for:

That little lot took me 5 hours! - but by then I was completely wrecked, decided to stop there and after a bath took the Golf for a drive.

My test route was 16 miles, with motorway/dual carriageway/B road, impressions of the Sportcat were much more eagerness to rev, with quicker throttle response.
ARB - they are behaving as I wished, the rubbing on hard sudden turn-ins has been removed and body roll minimised.
On the drive I found the rear end to be a lot livelier, suspect I need to take care with rear end stepping out in the wet.

VCDS seems our best bet, I'll do some googling.

Thanks fella - I am trying coding out cold diagnosis of the license plate lights discussed here: https://forums.ross-tech.com/index.php?threads/1073/ (https://forums.ross-tech.com/index.php?threads/1073/)
Unsure if that works with standard Mk5 Canbus, that thread is for a Mk6 chassis, but mine are newer canbus.

Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: colesey on July 19, 2021, 04:37:50 pm
Sorry to be the bearer of bad news, however the original ARB brackets modified to fit my front H&R arb cracked and came loose after a couple of years so I recommend you keep an eye on them. You can’t buy them separately otherwise, only as a full ARB assembly. That aside, the stiffer ARBs make a nice improvement in handling.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 19, 2021, 05:17:32 pm
Sorry to be the bearer of bad news, however the original ARB brackets modified to fit my front H&R arb cracked and came loose after a couple of years so I recommend you keep an eye on them. You can’t buy them separately otherwise, only as a full ARB assembly. That aside, the stiffer ARBs make a nice improvement in handling.

Thanks for the heads up - how much mileage/abuse did you put on them?
Have to say I chuckled at the H&R instructions saying "Avoid unusual or aggressive driving maneuvers that place excessive demands on the vehicle (racing events, etc.)"!
Maybe its lost in the translation, but what were the Germans thinking we were to to do with them?
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: colesey on July 19, 2021, 05:57:57 pm
Minimal use and abuse I’m afraid…
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 19, 2021, 07:38:26 pm
Minimal use and abuse I’m afraid…

Oh! - that's not great to hear - will source some spares
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: colesey on July 20, 2021, 07:33:29 am
Sorry to be alarmist - the issue in my car was on one side and there is always the possibility that the mechanic did something wrong. Not a bad idea to buy a used arb though to stash away for a rainy day.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on July 25, 2021, 04:19:17 pm
Got round to doing the Intercooler this weekend.

Seems Off side front corner has had a light bump, the fog light was different and held in by wood screws, and the headlight washer had been damaged - cable tie wizard had done their magic:
(https://i.vgy.me/U6KSK7.jpg)
Just leaving that as-is, its still working so no need to mess with it.

Bumper off I could see the condenser was in quite a state:
(https://i.vgy.me/JPnkmy.jpg)
As everything was being replaced, when screws rounded out I just cut off the connection to remove the condenser, it really was totally goosed:
(https://i.vgy.me/9GWaoF.jpg)
VCDS had been saying for months there was low pressure in the system, pleased that no gas came out when I cut into the pipes - service and re-gas booked for Wednesday.

Wrestling with the new Rad/intercooler/condenser set up I managed to forget to check that the 2 pegs at the bottom of the Intercooler were located in the slam panel - didn't find this out until after the bumper was on and I was wondering why the fans wouldn't spin freely... another go with front panel loose and it was in:
(https://i.vgy.me/HbLJiD.jpg)

Cut and fit the boost hoses, replace the rusted screws under the bumper with Audi stainless ones.
A bit of time bleeding the coolant - managed to save about 75% - then onto a test drive.
Much better throttle response than before, feels like there is a bit more power too.
Mid-range acceleration was always good, but now its much improved.
Title: Re: LC5F's Graphite Blue GTI - Sea Dweller Edition
Post by: LC5F on August 08, 2021, 05:33:01 pm
Update - managed to slip the timing belt and bend all 16 valves - covered in this thread:https://www.mk5golfgti.co.uk/forum/index.php/topic,131869.0.html (https://www.mk5golfgti.co.uk/forum/index.php/topic,131869.0.html)
Currently the Golf is sat stripped.

I have been gathering parts, so far I have got timing belt kit & cam chain kit both INA. Head gasket set & bolts both Victor Reinz. invested in a used Laser timing kit and new injector remover/install kit.
TPS has been taking a lot of money off me too, only things left to get are the ceramic rings that seal the VVT wheel on the exhaust cam.
The machine shop ~I will be using cant take the head till the 16th - so I just have to keep cleaning and reviewing the parts - plus bone up on cam chain and timing belt installs on you tube.

Its funny that looking at the parts taken off has uncovered a few porkies the PO told me, stuff he claimed he had renewed within the last year of his ownership - claims of timing belt and PCV were true, but the cam chain and diverter valve were definitely old - diverter is Rev C!

Today I was preparing the turbo - during my recent downpipe replacement I (wisely) body swerved replacing the studs. But as its now fully accessible I had no excuse, took blow torch and double nut to get all 4 out cleanly. Afterwards I chased out with a tap - a lot of crud came out of the threads and the new studs installed:
(https://i.vgy.me/B7cvjK.jpg)
After that photo I degreased all the grime off and turbo placed in the clean pile.

After converting to intake, the one thing that had been bugging me was the silly extended oil fill neck left from the engine cover:
(https://i.vgy.me/Q3W3ZZ.jpg)
Just looks daft!
Always thought it could be improved on...one of the YT videos was some dutch dudes doing a timing belt on an NA Audi A4, cam cover looked exactly like the Golf one, but oil cap was flush and it looked like it was alloy - after some searches on ebay I found it wasnt alloy (boo) - just plastic alloy - and it seemed to have plastic blocking the base of the filler.
Some googling and I found an old thread on here: https://www.mk5golfgti.co.uk/forum/index.php?topic=8036.0 (https://www.mk5golfgti.co.uk/forum/index.php?topic=8036.0)
Heat gun out, heating the base of the tube and then some taps with a hammer later:
(https://i.vgy.me/6ALKb1.jpg)
Oil cap is now flush & I can return back to extended neck if I want to - very pleased with this change
Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: LC5F on August 14, 2021, 08:18:01 pm
Finally got my hands on some proper degreaser to clean up the engine internals I still have while I wait for the head to be re-built, this is the varnish build up I have:
(https://i.vgy.me/B5WYnC.jpg)
Reminds me of this guy:
(https://alchetron.com/cdn/david-dickinson-b1531e2d-1454-4c07-a179-4d3170dcb2d-resize-750.jpeg)

I tried brake cleaner, spray degreaser, but it just wasn't shifting - decided I needed something stronger and a way to soak the cams.
Made up a trough out of rainwater gutter & 2 end caps, add Screwfix no nonsense degreaser -reviews compare it to Swarfegga Jizer, but only 1/4 of the price:
(https://i.vgy.me/ly6kIg.jpg)
and 30 minutes later the exhaust cam was clean:
(https://i.vgy.me/9Xil5e.jpg)
Rinse off with water, dry and spray down with wd40

Lifters and followers were next:
(https://i.vgy.me/WxfneK.jpg)
and after a soak and rinse:
(https://i.vgy.me/cS0Nab.jpg)
Now soaking in motor oil

Also cleaned and re-sealed the vacuum pump - got a Mr.Oring kit of ebay, arrived next day and was really easy to install:
(https://i.vgy.me/eNUPp2.jpg)
Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: Mekaniko on August 16, 2021, 11:15:42 am
What a rebuild now! All the best to this work! hope that the GTI is back stronger than ever.

good mod the oil cap with the lower position.
Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: LC5F on August 16, 2021, 09:03:40 pm
What a rebuild now! All the best to this work! hope that the GTI is back stronger than ever.

good mod the oil cap with the lower position.

Thanks fella - that's the hope
I'm really missing the Golf, fingers crossed the head will be refreshed for the end of the week
Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: den77 on August 16, 2021, 09:11:33 pm
Fantastic build really enjoying write up keep up the great work :congrats: :congrats:
Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: LC5F on August 17, 2021, 09:24:24 pm
Fantastic build really enjoying write up keep up the great work :congrats: :congrats:

Cheers for the kind words Fella

Had 2 phone calls today:
Injectors have been serviced - they were down on flow and now are back to expected volume.
The head is ready to be picked up, it seems my weekend is planned out.

However - I had not mentioned before but the turbo shaft had play, suspect oil would take up a lot of slack, I was nearly ready to just shove it back on, but with about 1mm play from centre side to side.
But as everything is off and despite trying to avoid falling into "whilst I'm in there" trap, I am going to rebuild the turbo with an uprated seal/bearing kit, won't make any more power, but should be able to take more abuse.
Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: Stupots on August 18, 2021, 08:52:19 am
@LC5F (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=49808) I'm trying to work out if your car or mine is more of a "Trigger's Broom" than mine... probably a lot of cars on here are.

I've replaced:
Front bumper/grill
Engine/Turbo
Battery
Seats/Door cards
Tailgate
Cluster
Steering Wheel
CAN Gateway
Head Unit
AC Controls
Glove compartment
Wheels
Shocks/Springs
Front and rear brakes (disks and calipers)

Still have in stock and ready to replace
Fuel filter + housing
Intercooler
Front alloy wishbones + Hubs
Anti-rollbars
Uprated turbo

I do think the Mk5 is hard to beat. I've owned mine 6 years and have no intention of replacing it... Well maybe bit by bit  :grin:

I always look forward to your updates, keep us updated  :happy2:
Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: LC5F on August 18, 2021, 06:58:17 pm
@LC5F (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=49808) I'm trying to work out if your car or mine is more of a "Trigger's Broom" than mine... probably a lot of cars on here are.

LOL - yeah I think we are close, but I've not done much body or interior, so you are winning there!

Managed to get my injectors and head back today:

Injectors all serviced and cleaned, I provided the VW service kits and the fitted it all together, provided a report on before and after flow rates, all 4 came up on the dynamic flow, static one stayed the same, 2 had a 0.85% increase and last one 1.69% increase - not much but good to know they are healthy:
(https://i.vgy.me/Gf7cE7.jpg)

Head has been rebuilt -
I tried buying a used head on ebay, but judging by the smashed plastic in the intake and 3 cam journals galled - the engine it came from must have been in an accident and got starved of oil. I was offered a replacement, but decided to rebuild my original head using the valves off the ebay one:
(https://i.vgy.me/v5qB8B.jpg)
The engine builder really enjoys cleaning stuff:
(https://i.vgy.me/xyhJiT.jpg)
(https://i.vgy.me/H8nc0V.jpg)
(https://i.vgy.me/5ESsRz.jpg)




Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: LC5F on August 21, 2021, 03:32:55 pm
Hopefully got the last parts required this morning from TPS, arriving home I got stuck into assembling the head:
(https://i.vgy.me/fAGTNV.jpg)
It went well everything went together, used Graphogen assembly lube on all the moving bits and the cam cage sealed up with the Victor Reinz sealant.
Installing the new ceramic seals for the VVT hydraulics was not hard at all.
Cam chain was a bit tricky needing both cams turning - watched a lot of YT films, really don't understand why people reach for grips when an 18mm spanner will turn the cams.

The hope of installing the head this weekend has been scuppered by the weather and the realisation the polydrive bit I got for the cam bolt is too big to clear the cams or even fit inside the head casting - so yet another special tool has been ordered - 3 days postage so fingers crossed for next weekend.

This is the current state of the assembled head:
(https://i.vgy.me/otE9TA.jpg)

Close up on the open valves with 3 angle ground valves:
(https://i.vgy.me/1fu1wL.jpg)
(https://i.vgy.me/7Ro4DE.jpg)



Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: LC5F on August 22, 2021, 06:44:03 pm
The rain finally stopped, it took till early afternoon before it dried out enough to get under the Golf.
As I am waiting on the head bolt tool + I have sent the turbo turbine away for balancing too - I have to try to get ahead on the tasks while I wait.
So today it was the sump and oil pick-up -
Currently the engine is in a state ready for head & timing belt to be installed - so the engine mount if off and the block supported by a spare rear spring under the sump, so I had throw the engine mount back on finger tight and sump unbolted - the bolts hidden up next to the flywheel are a PITA!
My driveway has an incline + Golf is on axle stands under the subframe, despite this I was surprised how much oil was still in the sump:
(https://i.vgy.me/P40E1l.jpg)
550ml - no wonder my oil goes black so quickly with that much still in the sump, probably a 1/4 of a litre in the vacuum pump too:
(https://i.vgy.me/2XsL5A.jpg)
Crud and varnish build up all around - black sealant around the bolt holes suggests someone non-VW has been in there, I wonder what they were doing?:
(https://i.vgy.me/ihCCPl.jpg)
After a lot of scrubbing with the degreaser it was clean:
(https://i.vgy.me/Fhg4fv.jpg)

Pick up had the usual build up:
(https://i.vgy.me/ytCW1M.jpg)
Soaking in degreaser:
All clean:
(https://i.vgy.me/IEoymE.jpg)
New O-ring, thread lock and back on:
(https://i.vgy.me/y3TSPQ.jpg)

I have to say I really don't enjoy RVT gasketting - I stress about putting too little or too much and then when it comes to assembly it always seems 50/50 for something going wrong  -  the cam cage yesterday was fine, but this time I managed to catch a little of the sealant on the plastic oil guide thing next to the oil pump at the front of the block... lets just hope its sealed.
Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: G-olf on August 24, 2021, 07:05:47 am
Looking good, bet you can't wait to be up and running again  :smiley:

Sump and pick up pipe clean is also on my list. Had much sealant squeezed out on the inside when you took it apart?
Did the pick up gauze clean up fairly easy?
At least it will have chance to set nicely as you don't have to run the engine straight after.
Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: LC5F on August 24, 2021, 04:53:40 pm
Looking good, bet you can't wait to be up and running again  :smiley:

Sump and pick up pipe clean is also on my list. Had much sealant squeezed out on the inside when you took it apart?
Did the pick up gauze clean up fairly easy?
At least it will have chance to set nicely as you don't have to run the engine straight after.

Yes - I've had itchy feet for a few weeks now - really intrigued how it will drive with all these many improvements.

Pick up is really easy to clean - I can't understand why some people buying a new one, that is unless there has been some failure they are fixing - I understand they are over £40!

It is stainless, I just dunked it in the £9 Screw-fix no-nonsense de-greaser and left it there for 30 minutes, then picked it up scooping fluid and allowing it to drain through the mesh few times and then back in to soak for another 30. Then took it out rubbed the mesh with a paint brush and then reverse rinse under cold tap and I could see the flow improve with each rinse.

How I messed up the sealant - On the front of the block there are 2 brackets that hang down at the side of the sump - one carries the secondary coolant pump - if possible I would recommend unbolting them and pulling them away from the sump - it would have made cleaning the block easier + easier to fit the sump.
And I should have practiced placing the sump into position a few times without sealant...

In other news-
The Turbo shaft and impellers should be back from balancing with me by Friday. Shaft was inspected when they received -  the shaft and the oil seal were scored... new shaft required, so more monies!
The head stud tool is on its way (Yay!), but it's being delivered by Hermes (Boo!)
- So I will be pleasantly surprised if it arrives on time.
Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: Mekaniko on August 25, 2021, 06:12:05 pm
 :congrats: :congrats: :congrats: :congrats: nice work in progess!

Reagrding the pick-up, on a workshop is cheaper for them to just change as it if they need to charge the labour of cleaning the part it will be the same same price maybe...but I take note for mine!

Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: LC5F on August 25, 2021, 09:39:46 pm
Well, I'm pleasantly surprised - hermes showed with the tool this afternoon.
This evening I installed the head, cam sprocket, vacuum pump, coolant flange and injectors - only issue was lining up the locating studs took a few goes, but everything else was good and the result is:
(https://i.vgy.me/r277ZP.jpg)
In the head gasket kit I have a 3 mystery O-rings - I can only assume these are for the vacuum pump??
(https://i.vgy.me/Ew4zx6.jpg)

The remaining work will be split into smaller chunks of:
Timing belt, covers, engine mount & drive belt
Re-install intake
Rebuild turbo and re-install

Reagrding the pick-up, on a workshop is cheaper for them to just change as it if they need to charge the labour of cleaning the part it will be the same same price maybe...but I take note for mine!

Thanks - I would say my actual physical contact with the pickup was less than 5 minutes - an hour just soaking by itself.

Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: LC5F on August 29, 2021, 10:47:23 pm
Thursday - added the timing belt and engine mount
Friday - installed the intake manifold, the rather dramatically named satan bolt was easy to do up with the dip stick tube removed:
(https://i.vgy.me/irtLNt.jpg)
lost a 1/4 drive T30 bit out of my set while installing the throttle - hopefully it will extract itself and get caught by the undertray.
(https://i.vgy.me/WfKeKB.jpg)
Balanced turbo turbines were delivered - just need to line up the markings:
(https://i.vgy.me/qWB6UM.jpg)
Saturday - turbo rebuild, kept finding it jamming once the nut bolted up, worked out it the issue was I was using the original oil deflector and the diameter was different, once the new deflector shape was adjusted it all went together.

After going to so much trouble it seemed silly putting some 22 month old spark plugs in + I needed G13... so another trip to TPS, surprised the VW have moved to pre-mix - more packaging / more volume /  more weight / more transport cost / more cost to end user - bit of a non-environmental richard head move VW.
Bit surprised to see NGK's have been dropped for Bosch:
(https://i.vgy.me/0e0c2s.jpg)
Got everything installed, filled up oil and coolant and spun the engine over with coil packs disconnected.
Connected up the coil packs and went for first fire - after a long clank it started to splutter and fired up - complete raket - huge manifold leak, I had not seated the turbo correctly! - I shut it off after a couple of minutes.

Sunday - Did a check for leaks in all the joints, pleased to say everything was dry.
Re-seated the turbo required all the manifold bolts loosened - for anyone following me, the key is undo the driveshaft at the box and then gives a lot more room.
All back together again, fired up and it was quiet, no strange noises apart from a ticking from the injectors and chatter from the drive belt tensioner - ran it up to 90 and everything was good.

Never heard the secondary coolant pump running after shut down, inspecting I found a pin-hole leak in the coolant hose next to the pump

Box of leftover bolts - the big 18mm ones are from the turbo heat shield - that I really can't be arsed to fit! I have no idea where the other T30 bolt comes from:
(https://i.vgy.me/wsAF3U.jpg)

How does it drive - well I had done so much to it just before it ate the drive belt, it does feel very strange.
But it has lost its urgency, I suspect I may be a tooth out in timing - at this stage after 5 weeks I am just relieved it's all back together
Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: pudding on August 31, 2021, 09:57:12 pm
Wow, what an epic transformation and a complete battle of the crusties.  Epic work  :notworthy:

That T30 bolt kind of looks like the lower vacuum pump to me, just above the inline stat, which also holds a wiring harness bracket in place.

Thanks for confirming the Rocco hubs cause rubbage. I'm not going to bother fitting mine now  :grin:

It should be proper peppy with head and turbo refreshes.  A tooth out on the timing ought to be fairly evident in VCDS looking at measuring blocks 91-93.  Cam phase position should be around 0-4KW and the actual and requested phasing angles should mirror each other quickly.  Maybe it needs more time to get oil everywhere.  When I replaced my VVT phaser and chain etc, it did take a while of idling and revving/ECU adapting for the numbers to all come good.

Keep at it, you've done some sterling work there  :drinking:
Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: LC5F on August 31, 2021, 10:43:09 pm
Thanks @Pudding (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=10733)
its been a slog - a tooth out is a lot better place to be than where I was a month ago - will dive into my VCDS and see what is saying.
Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: pudding on September 03, 2021, 01:42:17 pm
 :happy2:

Good luck with it.  If the timing drift is severe enough, it should throw a "Cam/crank correlation" fault code and you'll know immediately.  And also if block 91-4 (I think - cam phase position) doesn't show a reading at all - which will put it in "rich as fook, no VVT, bugger all timing and limited boost" party pooper mode.

The first time I replaced the chain on mine, I didn't know what I was doing and ticked the "seems about right" box, let's start it.  After 5 seconds or so of deathly rattling, it all came good.  I had gotten away with it  :grin:

It is amazing how utterly crap they can run when things aren't 100% though.
Title: Re: LC5F's Graphite Blue GTI - The exorcism of David Dickson Engine
Post by: LC5F on September 03, 2021, 06:04:45 pm
Good shout on the spare bolt - I saw the same bolt in the the timing chain DIY - this then found the spare upper cam bolt, that then found a spare silver T30...must be lower timing cover bolt I missed!

My VCDS gave me figures outside your range + 93 wouldn't give any phase - I run my VCDS on a net book, no net connection...feel very old posting a photo rather than snip of the screen!:
(https://i.vgy.me/0l3mK7.jpg)

Well, finished work and pulled the Golf into its service position on the drive and started pulling everything off to get to the timing belt.

And also if block 91-4 (I think - cam phase position) doesn't show a reading at all - which will put it in "rich as fook, no VVT, bugger all timing and limited boost" party pooper mode.
To ease engine turn over - I pulled the plugs and considering I have done only 10 to 15 miles they are sooty as fook!,  didn't mention it took longer cranking to start too - too much retard
Upper cam pulley positioned gives - slightly squint, but I lined up the inner side of the pully with the arrow:
(https://i.vgy.me/R63gAz.jpg)
and then diving down below I have:
(https://i.vgy.me/MYEnN4.jpg)
So I am a tooth out!
I only have engine mount, pulley and lower cover to take off and I will be at the belt again - its now very much beer o'clock... so that will be sorted tomorrow.



Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: LC5F on September 05, 2021, 04:16:14 pm
Saturday -
spent the day ducking in and out of the rain the met office were not predicting, it took 5 or 6 goes to get the timing to this:
(https://i.vgy.me/06YvhR.jpg)
The problem was I would locate the belt, but this would change after adding tension + doing the the double turn of the crank would lose the markings - I ended up marking the desired belt and crank pulley, slackening off and moving the crank 90 degrees clockwise and then back again to keep the markings in place.
I was surprised that there is a very slight off-set at the crank.
Early evening I finally got everything together - the spare silver cam cover bolt was the one that screws into the water pump under the engine mount - so no unknown bolts.
Start up was straight away, no long crank - first drive was frustrating, to give more room I had removed the turbo outlet pipe, I had pulled the clip of the silencer outlet out and I had not checked it had clipped back in.
I got 50m down the road, fist boost and I got a very load Pssssssst as the hose got pushed out!
Sunday -
Fixed the boost leak, and then went for a drive with VCDS running:
(https://i.vgy.me/bvOShJ.jpg)
Its better than before, just not as responsive.
@Pudding (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=10733) how long did it take to get the hydraulics to start working?
Edit - Since this post, I went for a 40 miles drive mixed roads different speeds

While installing the cams, I know the internal spring loaded clip in the hydraulic ring was activated and suspect it is sitting currently locked in the fixed position - 91 cam adjustment will only change by a degree, otherwise it seems locked to 54.

Treated the Golf to a good wash - think it must have been April when it last got a wash:
(https://i.vgy.me/1lC0EC.jpg)

Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: pudding on September 06, 2021, 05:40:22 pm
54KW at idle, wowsers!

I think what might have happened is you timed the cam chain/VVT stuff with the timing belt being off, so it's a double whammy.  You might need to go back under the chain cover again mate and reset the VVT timing with the timing belt in the correct position.  This should bring you back down to 28KW again.

In it's current timing, it would appear the ECU has no idea where the cam is in relation to the crank, hence no reading in block 93.  It's probably why it's not attempting to retard the VVT.  It's locked at 6% duty and shrugging it's shoulders.  Any movement at all when you rev it up?

Yeah it's normal for the crank pulley to be ever so slightly off when the cam sprocket is lined up correctly.

Lol, I did exactly that with the boost clip last year.  A loud bang followed by a few hundreds of crawling down the road into a layby  :grin:  Luckily I ended up outside a garage and they lent me a jack and some tools, phew!

Mine was stuck at 35KW for about 2 minutes (from cold) and wouldn't retard with revs.  I thought Oh sheet, I've buggered the timing, but I turned it off, restarted it, reconnected VCDS and then it came good.  Block 93 shows -3KW.  I've never been able to get it to 0KW (the theoretical perfect position) but after 160K miles of slop and wear, I'm happy with -3.  The acceptable 'tolerance' is +6 to -6KW I believe.

Still only moving a degree or so after the 40 mile trip?  If so, it's going to be another visit under the chain cover I'm afraid.   Hopefully it'll just be a retime, at worst one of the oil control rings might have snapped when sliding the chain cover back on, therefore the VVT isn't getting enough oil pressure.  I believe the middle ring supplies oil to the VVT chambers and the outer 2 rings control advance/retard.

What a pain in the hoop.  Far simpler having just one chain do everything instead of a belt AND a chain.  VW eh?  :grin:










Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: LC5F on September 06, 2021, 06:19:38 pm
Thanks @Pudding (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=10733) - Thanks for confirming the crank being slightly out, was starting to think the cam may have twisted - This vid is terrifying:


Yes - I think something must have had gone awry with the chain install.
Every film on YT the guy tweaks the intake cam and with a bit of faf on it goes with just the one person -  I had to turn both cams with my wife installing the ring.

Oh well - at least it's not the belt again and the head is now firmly attached to something - not floating around on my kitchen island!

Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: pudding on September 07, 2021, 09:46:56 am
I had to read the comments on that vid to understand what was going on, but crikey, that is a bit crap isn't it  :surprised:   Amazing these engines last as long as they do with all their common faults!

Yeah the intake cam rotates a few degrees when you remove the chain because of the valve spring tension, but the cam locking tool 'catches' it.  I mark the intake cam with a sharpie next to a cam cap, and I'd say it flips back (anti-clockwise) approx 4-5mm.  That is what needs tweaking back again whilst wrestling the VVT sprocket on, as you've seen in the videos  :happy2:   

It's definitely easier with 2 people, but doable with one person.  Good job your missus was around to assist!  Mine would never tear herself away from Love island to help with car jobs  :grin:


Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: LC5F on September 07, 2021, 08:30:11 pm
Thanks @Pudding (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=10733)  - it wasn't easy getting the help, I had to coerce - getting the head out/off the kitchen/island was the carrot!

Please can you confirm that the cam locking tool should easily slip out and that it locks the cams in TDC?
Mine were tight to take out after the cam install - and it may be the paranoia, but if its meant to be TDC I could check its not spun the cam
Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: pudding on September 08, 2021, 08:58:49 am
 :grin:

The locking tool should drop in and pop out with no resistance when it's timed correctly I'm sorry to say. 

I really hope the cam hasn't spun.  The video seemed to imply that only happens when you get oil starvation (blocked pick up)?  Then again, didn't you have some unhappiness going on under there with the sheared off VVT locating pin?

I would suggest giving the chain timing another go and if it still doesn't line up correctly, I think it might be new exhaust cam time for you  :sad1:

What a ball ache.  Kudos for sticking with it  :happy2: 

This is what you're looking for when it's all set.

(https://live.staticflickr.com/65535/51434922952_91050a6fd5_k.jpg)
Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: LC5F on September 09, 2021, 04:56:35 pm
I was going to wait till the weekend to look into this, but the not knowing was niggling me, so dived in today.
Of all the engine dismantlement states - this is an arrangement I have not tried before:
(https://i.vgy.me/0kgwNJ.jpg)

Exhaust Cam pulley aligned with the arrow, tried 1/2 extension sits perfectly vertical between cylinders 3 & 4, plus the No.4 exhaust cam is sitting at 45 degrees - that's good, I don't think my cam has twisted - but the intake should be a mirror the angle of the exhaust lobe, but it's only 30 degrees up:
(https://i.vgy.me/z5pVbS.jpg)
Hopefully this is it - looks like something did go wrong in the chain install, hopefully I can sort this at the weekend.



Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: pudding on September 10, 2021, 10:53:58 am
Yeah flip the intake cam round a tooth and it should come good again  :happy2:

Glad the exhaust cam isn't busted.  I think that video is maybe highlighting an extreme failure. It would be far more prevalent if it was a 'common' issue.

Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: LC5F on September 10, 2021, 07:53:38 pm
Well, I was enthused by knowing  I cracked on today, HPFP and VVT cover off, and then onto undoing the ring bolt:
(https://i.vgy.me/94q5w3.jpg)
I commented on people using grips - but it does make sense to hold the cam in TDC.

I now know where I went wrong - I did not have the cam pulley or rear cam cover with TDC mark installed - if I had them and locked the exhaust cam in position I do not think I would have gone wrong with the chain.
The so called "cam locking tool" doesn't really lock and allowed a lot of rotation of the cams, I was using the more american counting chain links - a lot of confusion out there.
Reading the guide on here and one or 2 YT vids that don't count the links I just got on with it - I did still mark the links as a final check.
Literally first go, a slight turn of the intake cam and in it went - so easy! - and the chain marks lined up:
(https://i.vgy.me/FiV5Rw.jpg)

And the cams are now like this - nice and symmetrical with a slightly higher intake:
(https://i.vgy.me/7HZL86.jpg)

Really chuffed - I just got stuck into getting everything back together all was good apart from the HPFP banjo bolt - I thought the threads had caught with 1/4 inch drive...decided I would try turning it with my finger tips...pulled the bit out and the banjo bolt stayed put for half a second before dropping down somewhere inaccessible - eventually found it, it took a magnet to get it out.

and the VCDS money shot:
(https://i.vgy.me/doCxJ1.jpg)
Golf is still on the drive way, but just revving feels a lot more responsive.

All I have left is fish out some stuff I had dropped from the engine undertray, re-install the side engine cover and then drivers front wheel and I should be properly back on the road.
Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: pudding on September 11, 2021, 12:05:48 pm
 :congrats:

0KW phase position, top work  :happy2:

Yeah that cam locking tool is hideous.  If it were a normal 16V engine with 2 cambelt sprockets, you can wedge something in between them to lock them together, but nope, VW do things the hard way  :grin: 

Clearly the TDC accuracy isn't THAT critical if they made such a sloppy tool.  Maybe the VVT tweaks itself to get it spot on but obviously it can't be a tooth off physically for that to work.  I remember the R32 timing being the same.  It would always be a around -3 or -4KW (instead of 0) after a new chain but it didn't affect the performance.

Blimey, even the mole grips and VVT phaser have been attacked by the famous Scottish rust  :grin:

Anyway, good work and persistence, it'll be a different car to drive now  :happy2:

Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: LC5F on September 11, 2021, 01:30:39 pm
@Pudding (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=10733) Thanks for the support - really helped work out what / where I had gone wrong.
BTW Those Vice grips are about 30 years old, just worn in!

Last bits done this morning and the Golf is feeling more itself with instant throttle response returned - all the fixes has definitely given it a bit more go, it now seems very happy to light up the front wheels.

Still feels odd (in a good way) as I had not got used to the new intercooler, sport cat downpipe, uprated ARB's and a pair of PS4's on the back - a lot to get used to.

And how does the Golf repay all this love and attention lavished on it? - intermittent Front Right ABS signal!



Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: pudding on September 11, 2021, 01:49:54 pm
No worries, glad my ramblings helped in some way  :grin:

I'm now wondering if my exhaust cam has tweaked slightly (as per that video) as I can't get mine to 0KW no matter what I do  :grin:

Check that again after some miles and see if it's drifted a little, but either way, you got it bang on sir and absolute confirmation your exhaust cam hasn't shifted  :happy2:  Annoying that it took a couple of attempts but you've gained a ton of knowledge during the journey  :happy2:

Oh dear, out with VCDS again!  Hopefully just an unhappy wheel sensor!  Your car is certainly making you work hard for it's affections  :grin:

BTW, I like the MAF sensor position on your intake kit.  They've moved it away from the turbulence of the turbo wheel, nice effort, no other intake maker considers that :happy2:  What are long term trims like with that kit?  Block 032 in VCDS.  It looks like a good one to me.
Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: GVK on September 11, 2021, 05:33:38 pm
Great update! :congrats:
Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: LC5F on September 11, 2021, 07:52:46 pm
Thanks @GVK (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=516)

@Pudding (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=10733)
Went for a run this evening to capture 032 and read 033 is a good health check too - unsure how to interpret  the numbers though!
Unsure if its a good test period - problem is I'm in the city and tricky to open it up to give a more varied use - Any way this is after start up:
(https://i.vgy.me/Ji4kj4.jpg)
And after a longer run around the block it reported:
(https://i.vgy.me/MAh6Gj.jpg)

Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: pudding on September 14, 2021, 08:54:26 am
So far so good  :happy2:   You will definitely need a lot more miles on it to get a better picture, but those numbers basically just mean fuelling tweaks the ECU has to make to get the actual and requested lambda numbers to match.   The bigger the numbers, the worse the intake is as it generally points to the MAF scaling being completely wrong, which is a common problem with aftermarket kits.

So long as neither exceed 5%, all is good  :happy2:
Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: LC5F on September 19, 2021, 04:38:01 pm
Golf is in its MOT window so need to keep everything sweet - the ABS error seems to have calmed itself down and has not flashed up for a week or so - hopefully I only have the blown bulb warning to worry about - that pops up randomly with the Mk7 LED number plate lights.

To complete the overhaul, I still have Passat alloy hubs and new bearings to fit, bought new ABS sensors to fit with the hubs, if the ABS warning re-appears I will swap out the sensor - hubs can wait until after MOT, just incase I cut/nick a boot on a ball joint or track rod end.

Sourced an INA drive belt tensioner, like the timing chain tensioner it has the VAG PN ground off:
(https://i.vgy.me/BUb9Ee.jpg)

Found a temporary cable tie mod to keep the drive belt in place while removing the tensioner... all to avoid jacking up, removing the wheel and dropping the undertray... worked great until I dropped the bottom most bolt while pulling the tensioner out. out came the jack, wheel off, but had success with telescopic magnet to fish the bolt out:
(https://i.vgy.me/UOIeDt.jpg)

New tensioner has really quietened down the engine a lot, the pulley on the old tensioner had only a very small amount of play, but this creating a fretting noise and I could see the arm moving around - making a lot of noise

I have now had the Mk5 for nearly 2 years, decided to treat it to a new cabin filter, the old filter was replaced not long after purchase, it was full of tree debris so due for change:
(https://i.vgy.me/OjpTql.jpg)

I didn't realise that hidden under cardboard in the bottom of the crate my head came back in were my old valves, they are a bit more bent than they were after belt slip - valves were jammed open with springs compressed - so to get the collets out the valve had to be hammered over to allow the spring to be compressed:
(https://i.vgy.me/ebb3Gt.jpg)
Seemed I was very much due a de-carbon - at least that is a small win!:
(https://i.vgy.me/zpcq3U.jpg)



Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: LC5F on September 29, 2021, 07:32:50 pm
MOT booked... thought everything had calmed down, but there was nothing at my conveniently close garage till 16th of October! - used to be booking within a week.

Been peering into how many writes the ECU on my engine and DSG box have with VCDS, an unmolested ECU should be zero:
(https://i.vgy.me/s7Kzj5.jpg)
(https://i.vgy.me/INO1lW.jpg)

So both have 1 programming attempt/success - I can only assume my Golf is remapped with a generic map

Always suspected the gearbox had been tweaked, it's really good shifting to suit throttle/demand (just how Revo describe their map), in comparison the wifes C7 A6 is also Audi DSG and its very different, slow changes and holding on to gears when it shouldn't.

But the engine power has always just been OK - it feels like standard power, on boost power is OK, but gets delivered in a big lump...could just be the Mk5 being a lot smoother/quieter to previous turbo cars.

Got me thinking it may be a Revo map, reading up the map get reset to standard after battery removal, seemed to make sense... Plus the Golf has always been a Scottish car, the most widespread tuner up here North of the wall is Revo.

Contacted them and they were kind to check...sadly they replied with a no - so I have a mystery remap
Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: pudding on October 01, 2021, 12:14:50 pm
Mine's in for MOT now.  Got given a god awful Up! as a loaner  :grin:  I know it's a cheap car, with only 30K on it, but it feels and sounds about 10x older than my GTI  :grin:

Anyway, well done on the cable tie trick, that's what I do  :happy2:  I don't even like jacking the car up to do an oil change, let alone a belt!

Those intake valves aren't actually too bad, in terms of carbon build up. I've seen a lot worse!

Interesting on the remaps.  You could look through the history and call the dealer(s), or HQ, to see if it had a dealer update at some point?  It will be on their records if it has.  I'm not aware of any dealer applied ECU updates (mine's never had any) but you never know.



Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: LC5F on October 16, 2021, 12:45:48 pm
Pleased to say the Golf the passed its MOT -
I was a little nervous of my new PipeWerx sport-cat downpipe, been reading a lot of alarming reports on here of these failing their first MOT...
But shouldn't have worried, it provided CO figures of:
Fast idle - 0.07% - Maximum of 0.20%
Natural idle - 0.04% - Maximum of 0.30%

Typical - last night after a sudden burst of speed the ABS light flashed up and went away...cleared it this morning and took it for a 20 minute drive before dropping the Golf off 15 minutes before MOT appointment.

Only one advisory - sticking off-side handbrake cable - hopefully that can wait till spring, will replace both at the same time - fingers crossed we don't get snow, my Mk5 is the best car I have ever had for hand brake turns.

Those intake valves aren't actually too bad, in terms of carbon build up. I've seen a lot worse!

Interesting on the remaps.  You could look through the history and call the dealer(s), or HQ, to see if it had a dealer update at some point?  It will be on their records if it has.  I'm not aware of any dealer applied ECU updates (mine's never had any) but you never know.

Yes - seen much worse valves too, but feel they were cruddy enough - if they hadn't been destroyed - I would have wanted them cleaned.
Are you saying it possibly a dealer update rather than re-map? it has a lot of dealer stamps in it its service book.
Got some time off next week, may make a trip out to the dealer with something to bribe them to look the information up
-Halloween is great for cheap sweets!
Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: JoshB on October 21, 2021, 02:41:06 pm
Pleased to say the Golf the passed its MOT -
I was a little nervous of my new PipeWerx sport-cat downpipe, been reading a lot of alarming reports on here of these failing their first MOT...
But shouldn't have worried, it provided CO figures of:
Fast idle - 0.07% - Maximum of 0.20%
Natural idle - 0.04% - Maximum of 0.30%

Hooray! Those are some cracking numbers for a sports cat... do PipeWerx use MagnaFlow cats do you know? Every car I’ve ever had with a MagnaFlow cat on has passed its mot and I’m pretty sure this one on my MPD downpipe is.
Title: Re: LC5F's Graphite Blue GTI - Tooth Fairy Visited
Post by: LC5F on October 21, 2021, 05:50:27 pm
Hooray! Those are some cracking numbers for a sports cat... do PipeWerx use MagnaFlow cats do you know? Every car I’ve ever had with a MagnaFlow cat on has passed its mot and I’m pretty sure this one on my MPD downpipe is.

Cheers -
I was going to say I didn't know... but remembered I did snap a picture of the CAT PN and googled... you are correct, it's a Manaflow 59959:
https://www.magnaflow.com/products/59959-catalytic-converter-magnaflow-standard-grade-federal-epa-compliant-universal-catalytic-converter (https://www.magnaflow.com/products/59959-catalytic-converter-magnaflow-standard-grade-federal-epa-compliant-universal-catalytic-converter)

Thanks for the prompt - it's good information to know and have the confidence that it should provide years of good use.
Title: Re: LC5F's Graphite Blue GTI - MOT'd to the Max!
Post by: pudding on October 22, 2021, 09:53:14 am
Nice  :happy2:

Yes Magnaflow and Borla cats pass MOTs no problem.  Being American, they have to be California compliant......the strictest air quality regulations in the world.

Years ago, boring story bro, I built a Corrado VR6 turbo and the only aftermarket cat that got it through an MOT was a Magnaflow cat from a truck. A large square one, not the barrel design like the one linked, but that one looks great for building your own DP  :happy2:  Notice how cheap exhaust parts are in America compared to rip off UK!

Not ALL aftermarket cats fail the UK MOT, and not always on the first test. But many of them require excessive warming up prior to the test, and fail on the 2nd, 3rd or 4th test.

The Magnaflow one just breezed it.  No need to rag the sh1t out the car round the block 3 times prior to hooking up the gas analyzer.  Every single time I've used a sports cat (even a GESI one - often touted as the best), the tester always comments on them being borderline.

Anyway, cats schmats.  Boring topic.

Yeah it may just be a dealer update.  Just bought a MK6 TDI recently and that's been flashed.  Unfortunately we need VAS-PC and/or ODIS to compare the ECU file to what's on VW's firmware servers to be 100% sure.






Title: Re: LC5F's Graphite Blue GTI - MOT'd to the Max!
Post by: LC5F on October 24, 2021, 05:56:15 pm
Today -
Installed under seat drawers yielded from a recent scrap yard trip.
Fixed a clunking noise in the nearside door that occured turning left/right and a speaker crackle in the offside - both were the speaker cable adaptors similar to type shown below flapping about - some double sided number plate pads stuck them in place - no more clonk / or crackle:
(https://encrypted-tbn0.gstatic.com/images?q=tbn:ANd9GcRuv6eRuUbhsEP7DFrQSzxyexueQXc7gzRl-g&usqp=CAU)

Plus I had a little windfall a few weeks ago, invested in a GFB DV+ - pleased to report improved boost as expected, on off throttle greatly improved

Title: Re: LC5F's Graphite Blue GTI - MOT'd to the Max!
Post by: LC5F on October 24, 2021, 05:58:08 pm
Nice  :happy2:

Yes Magnaflow and Borla cats pass MOTs no problem.  Being American, they have to be California compliant......the strictest air quality regulations in the world.

Years ago, boring story bro, I built a Corrado VR6 turbo and the only aftermarket cat that got it through an MOT was a Magnaflow cat from a truck. A large square one, not the barrel design like the one linked, but that one looks great for building your own DP  :happy2:  Notice how cheap exhaust parts are in America compared to rip off UK!

Pictures?
Title: Re: LC5F's Graphite Blue GTI - MOT'd to the Max!
Post by: pudding on October 27, 2021, 01:45:53 pm
Nice one with the speaker crackle fix.  My passenger side has been doing that for years but I can't be bothered to take the door card off, or is it a door skin off job?

Here's a few.

I went through the whole modding program with it, starting with n'asp mods, supercharger, turbo and finally an R32 conversion.

The turbo conversion was just stupidly fun. I limited it to 400hp to keep the gearbox in one piece and it lasted 60K miles like that.  Other guys at the time (over 10 years ago now, sheesh) were running 500,600 and more from the same turbo (Garrett GT35R) but were eating gearboxes, CVs, driveshafts every few months.

After a bit of a stupid mapping error on my part, I blew the turbo engine. Rather than rebuild, I fancied a change and chucked the R32 in, but in hindsight it was a bad move.  A really, really boring engine.  R32 conversions were popular at the time because 12V VR6 parts were scarce (even from VW) so I sold it on easily enough.

Fun times, but never again  :grin: 

(https://live.staticflickr.com/4888/44416552960_fe664ffd4a_b.jpg)

(https://live.staticflickr.com/4810/45320880605_a375b0790d_b.jpg)

(https://live.staticflickr.com/4869/44416553070_3b2889abe1_c.jpg)
Title: Re: LC5F's Graphite Blue GTI - MOT'd to the Max!
Post by: LC5F on October 27, 2021, 07:51:37 pm
(https://live.staticflickr.com/4888/44416552960_fe664ffd4a_b.jpg)

Cheers - Nice colour - always had a soft spot for MO's too.

Actually - forgot, I have a mate up here in Scotland doing a big turbo 12v in a 4-motion Mk4 shell - he's very talented, adapting 1.8t management to run the VR6
Title: Re: LC5F's Graphite Blue GTI - MOT'd to the Max!
Post by: pudding on October 28, 2021, 11:48:26 am
Thanks  :smiley:  Ice Grey Violet is one of my favourite VW colours.  Not sure it would sit well on any other car but it certainly suited the Corrado.

4WD definitely recommended with a VR6 turbo, so that's a good move by him for sure.  That's an interesting choice of engine management and kudos to him if he gets it to work.  I used a standalone on mine as I preferred the freedom to tune it myself rather than having to drive for hours to a dyno.

OEM management has all the difficult tuning absolutely nailed out of the box (cold start, warm up, idle, part throttle, onset of boost etc etc) so I wouldn't recommend anyone mess with a standalone to be honest  :grin:
Title: Re: LC5F's Graphite Blue GTI - MOT'd to the Max!
Post by: LC5F on November 18, 2021, 07:51:46 pm
Fixed a clunking noise in the nearside door that occured turning left/right and a speaker crackle in the offside - both were the speaker cable adaptors similar to type shown below flapping about - some double sided number plate pads stuck them in place - no more clonk / or crackle:

No real news, except to report some fails:

The speaker crackle was hiding - returned mid week after reporting the fix. Following weekend dash apart and its a duff bullet connector - I going to have to solder the connection from amplifier cable to OEM loom.
-and-
The clunking... that came back... some head scratching, and a bit more thinking... it's the passenger seat belt buckle knocking against the door card!
Making sure the belt is around the outer seat back bolster and there is no clunking, its fine with a front passenger, but if there is someone in the back when they get out it re-sets the belt off the bolster.


Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on December 18, 2021, 12:41:30 pm
Just back from a 800 mile round trip to West Wales - usual random stuff found in farmer supply shops:
(https://i.vgy.me/345pYz.jpg)

The trip down was pretty un-eventful, other than the seat belt chimes randomly sounding despite both belt buckled up. Some quick research on here helped, being 400 miles from home I did the non-VCDS option of just disconnecting the  2 pin pressure switch plug under both seats.

Fuel - its difficult to maintain any average or low enough speeds to be economical, but I was happy Golf did just over 6 miles per litre on Sainsbury's premium, on the way back I tried Tesco Momentum - definitely got a bit more umph, will find out if it did better mileage when I fill up.
Oil - previous few similar trips were before the head & turbo rebuild, it would use at least half a litre of oil each way, that looks like the consumption has halved - approximately 0.6 litres per 1k miles.

Return journey back to Scotland was a bit painful:
My timing was not good - I joined the M5 at Worcester, managed to then hit Birmingham at peak rush hour, and then all the way up till past Manchester it was random stop starting in the fast lane -I was sat there waiting for a pile up with the other 3 lanes still rolling.
M6 quietened down at Preston, all good through the lakes apart from some light mist - this then meant several cars decided to put fog lights on and leave them on...

But then I got to Penrith - a numpty in an older Astra joined the motorway, pulled into the middle lane to over take a slower car he had followed down the slip road, with no other cars in front of him, just as I was about to pass he decided to pull into the 3rd lane I was in.
He was doing 70 - I was doing 80, to miss him I had hard swerve towards the barrier, had to swerve back, nearly went into a complete tank slapper - but after a couple more left / rights and the Golf collected itself.
I think it would have been a different story if I was still on standard ARB's - the H&R's just killed the body roll - without them I could have spun, rolled or anything in between.

Strangely, by the time I got to the Borders, I was sick and tired of motorway, I could not either wait till the A702 or the possibility of more numpties on there too, so I escaped early by diving off onto the A701.

Normally this is a great drive, but the mist made an unwelcome return, this time it was thicker and hanging about.
I was hoping it was just in the valleys and would clear once I got the the Devils Beeftub... but it ended up 50 miles driving at 30 to 45.
The good news it was completely empty, caught up with on Scottish gas van who pulled over near Biggar, and for the last 10 miles I was grateful to tail a transit, he somehow could see further so it was a lot less stressful just following at a good distance.

Now I just have to deal with the road muck:
(https://i.vgy.me/Q04Kjt.jpg)




Title: Re: LC5F's Graphite Blue GTI
Post by: LC5F on February 20, 2022, 11:02:57 am
What's in the box? - hopefully the fix to mental auto wipers and cruise control not always switching off:
(https://i.vgy.me/mjPUiP.jpg)

My wiper arm was always generating a fault code, replacement arm was required, couldn't see any point trying a used one as it could also be faulty and it would also be odd replacing wiper stalk and leave indicator stalk old....but then occasionally the cruise control wouldn't respond to input from controls, so both needed replacement

Removal was straight forward:
(https://i.vgy.me/JzlC8R.jpg)

Interestingly the the Febi indicator stalk has the VAG logos deleted:
(https://i.vgy.me/froWEs.jpg)

As the wheel was going to come off I thought I would make some improvements there too.
I love the original wheel, but find the leather lacks grip and feels like it could do with a bit more girth.
Scanning through Chinese ebay (somebody has to keep their economy going) I found a good looking alcantara wheel cover to fix my issues.
Current girth at thumb rest - front to back:
(https://i.vgy.me/fincwg.jpg)

Side to side:
(https://i.vgy.me/wm24cz.jpg)

Installing the cover was tricky, watched loads of YT films and got stuck into what ended up taking 6 hours!
With my carbon paddles I decided to strip the entire wheel down, this is half way having done the lower 2 openings:
(https://i.vgy.me/rUyv82.jpg)

I am reasonably happy with the result being OK, a lot better than some I have seen, stitching is a bit random:
(https://i.vgy.me/I4Dhw0.jpg)

Girth improvement, F to B:
(https://i.vgy.me/VAi4eT.jpg)

Side to side:
(https://i.vgy.me/h2Iqdf.jpg)

2mm improvement in both directions definitely feels better and the grip with alcantara is superb.
Currently I'm not 100% on board with the red stripe - I was swayed by a wheel TR Hamza installed in his Mk7

But my biggest annoyances are-
Around the DSG paddles - the seller did accomodate for paddles, but the fit isn't the best - the paddles used to give a nice mechanical click, the paddles still work but now the material is cushioning the paddles. Plus the fit on the Left side thumb rest has an exposed edge of the suede.
Currently it is a bit baggy & I have a couple of bubbles of suede in the stitching - hoping this will flatten out, but this may be it:
(https://i.vgy.me/toDnI7.jpg)

Think I will try black sharpie on the exposed edge.




 
Title: Re: LC5F's Graphite Blue GTI - a bit more girth
Post by: pudding on February 26, 2022, 01:08:23 pm
Great job on the steering wheel  :happy2: 
Title: Re: LC5F's Graphite Blue GTI - a bit more girth
Post by: RBS on February 27, 2022, 10:06:47 pm
Indeed looks great  :congrats: :congrats: :happy2:
Title: Re: LC5F's Graphite Blue GTI - a bit more girth
Post by: LC5F on March 06, 2022, 07:59:54 pm
@Pudding (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=10733) & @RBS (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=11390) Thanks for the kind words guys - I think it has shrunk a little, still got to try some light heat.

So last week I managed to sort out my spare key that I groke the chip in trying to convert it to a Mk7 shell.
Ended up going to Timpsons, typically the only guy in Edinburgh is the opposite side of town... usually they are one-man band arrangements, so I was wondering how he was going to scan my car - easy he sent me out with this reader on my key to gather the information:
(https://i.vgy.me/yL3BnZ.jpg)
£75 liter - I eradicated the stress of only having a single key.

This weekend there was good weather so manged to do an oil change, taking the full length engine under tray off was hampered by the middle bolt intot he subframe being filled with tarmac...got to stop attacking speed bumps:
(https://i.vgy.me/PZlX3R.jpg)
Thats with the torq opening picked out, luckily I had a spare bolt to shove in, the driver's side had also been attacked too:
(https://i.vgy.me/A5Y550.jpg)

Got to finally use the filter oil drain tool - it is the cleanest oil change I have done on the Mk5:
(https://i.vgy.me/IuTMVd.jpg)

One of the issues I kept on having pre-head rebuild was really high oil consumption, it was regularly getting very low - but the Golf was not giving any warning for low oil level.
From googling I found what I thought was the correct replacement sensor to go into the sump, managed to find a genuine new one on ebay maybe 4 months ago... I suspect I mis-googled as there is a bit of a difference in length... old one is on the right!:
(https://i.vgy.me/Sa0Zql.jpg)
I shoved the new one in - my logic may be flawed - but hopefully this one will warn if it gets too low, need to source another one for the next oil change.

Title: Re: LC5F's Graphite Blue GTI - a bit more girth
Post by: pudding on March 07, 2022, 08:46:19 am
I've seen re-trimmers use steam to shrink the leather tightly onto the wheel, as well as upholstery glue.  I'd be happy with how yours turned out though tbh, but a little heat won't hurt though!

Have you still got high oil useage after the head rebuild?

I never let the oil get low enough for the warning light to come on. I check it once a week. Probably why my dipsticks keep breaking  :grin:



Title: Re: LC5F's Graphite Blue GTI - a bit more girth
Post by: LC5F on March 07, 2022, 09:35:51 am
@Pudding (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=10733) - after the head / turbo rebuild oil consumption has dropped dramatically - before it was going through a litre of oil in 500 to 600 miles. Now it hangs around a lot longer, plus with me doing such low milage I only check maybe every month or so, last top up was only 1/4 of a litre.

The problem with artificial suede is it's machine washable, so moisture has no effect on it, currently the baggy bits are:
Right thumb loop- this is simply 4 to 6mm of extra material, that needs to lose itself...
Back of the flat bottom- amazing how often this gets touched during manoeuvres, a reminder/annoyance at every junction!
Title: Re: LC5F's Graphite Blue GTI - a bit more girth
Post by: pudding on March 07, 2022, 02:47:45 pm
That's a good improvement then.  I occasionally get a waft of burning oil when sat in traffic for a while, so I think I have the same job coming up.

Ah of course, steam won't work then  :grin:
Title: Re: LC5F's Graphite Blue GTI - a bit more girth
Post by: RBS on March 08, 2022, 05:14:49 pm
Job well done :happy2: :wink:
Title: Re: LC5F's Graphite Blue GTI - a bit more girth
Post by: RBS on March 20, 2022, 08:52:47 pm
How do I give you a like?
And how is the new steering wheel ? Enjoying it? :happy2:
Title: Re: LC5F's Graphite Blue GTI - a bit more girth
Post by: LC5F on March 21, 2022, 01:09:30 pm
How do I give you a like?
And how is the new steering wheel ? Enjoying it? :happy2:

Thanks - I do like it - I "think" its shrunk a bit on the right side, flat bottom is still baggy, will just have see how it progresses.

Well I have had quite a time improving my headlights over the last couple of weeks -
(https://i.vgy.me/27ij3y.jpg)

Not happy with light output - I had a lexus behind me one night, its lights were brighter than my own...
lights out I delved deeper into the Xenon units, all the wiring in good condition not hardened or cracked, removed the bowl and lense:
(https://i.vgy.me/UJpTb7.jpg)

I was expecting these to be burnt through without reflector, but they were mint! only issue I found was milkyness on the lense:
(https://i.vgy.me/3kjLXT.jpg)
Cleaned:
(https://i.vgy.me/vjSxeK.jpg)

Re-installed the bowls with new mid-range Xenon bulbs, and as the lights were out I replaced the halogen high beam & indicator bulbs - retained my LED side lights.

Outer Lenses:
I first tried a Holts restore kit, I chose this as it comes with lots of grades of sand paper and a drill attachment.
I read on here another person had experienced the kit creating more scratches - the box says that both sanding discs and drill attachment are 75mm  diameter, but the attachment is 80mm, leaving very hard velcro overlapping to scratch the lense:
(https://i.vgy.me/n4k0BP.jpg)

Took a lot of polishing to get these "new" scratches out, eventually got to the stage of adding the sealing compound, but didn't like the finish. Decided to lacquer the lights instead...but I was too heavy handed and ended up with drips...and didn't help that the heavy duty lacquer was slightly yellow...so I had to sand it all off:
(https://i.vgy.me/cpNWcT.jpg)

Ended up hand sanding these all down, polished them with the holts scratch remover and then ceramic coated the units... this had taken 1.5 weeks to get here!
But in sunlight it highlighted scratches still present, brother in law like his detailing, gave me Meguiar's Plastic RX and this finally got the lenses into a good enough state.

This is before, not too bad:
(https://i.vgy.me/pUhlyJ.jpg)
(https://i.vgy.me/ly6y0N.jpg)

After, not perfect, but a lot better:
(https://i.vgy.me/4BAzXx.jpg)
(https://i.vgy.me/tjLOR0.jpg)

Dipped beams light output before:
(https://i.vgy.me/BEnpKD.jpg)
After:
(https://i.vgy.me/19LAZe.jpg)

Side by side there isn't much difference before/after, my Xenon bulbs had degraded considerably.
In traffic I can now see the road in front, it's not drowned out by other light sources, I'm not thinking where has the road gone!

New toy - really good, set the pressure in either PSI, BAR or kPa and pull the trigger and it cuts off when it gets there:
(https://i.vgy.me/1LEqvZ.jpg).

Only improvement would be if it bled down over filled tyres, I had to manually let air out...but maybe I'm asking too much!
If you already have Makita LXT batteries, it's a cheap buy.


Title: Re: LC5F's Graphite Blue GTI - No eye Gti
Post by: jacksosi on March 21, 2022, 05:39:48 pm
Quote from: LC5F

Side by side there isn't much difference before/after…

You’re joking, you couldn’t see that blue car straight ahead before, great job
Title: Re: LC5F's Graphite Blue GTI - No eye Gti
Post by: RBS on March 21, 2022, 06:53:09 pm
Improved is an understatement!!
This looks AMAZINGLY beautiful :happy2: :happy2:
Great job!!
Title: Re: LC5F's Graphite Blue GTI - No eye Gti
Post by: LC5F on March 22, 2022, 09:53:13 am
Quote from: LC5F

Side by side there isn't much difference before/after…

You’re joking, you couldn’t see that blue car straight ahead before, great job

LOL - well played Sir1

Improved is an understatement!!
This looks AMAZINGLY beautiful :happy2: :happy2:
Great job!!

Thanks RBS
Title: Re: LC5F's Graphite Blue GTI - Handbrake fun
Post by: LC5F on June 03, 2022, 10:20:04 pm
Decided to take advantage of the jubilee weekend to do the remaining items on the Golf: Handbrake cable and Passat alloy hubs with new wheel bearings.
Wanted to get an alignment booked before diving into the hubs, left it too late and here we are with no booking and the place I use is now shut...never mind, dive into the handbrake cables.

I knew the removing the centre console was going to be a PITA, but I had not budgeted for having to remove the drivers seat!  Months ago, I purchased 2 supposedly the same Pagid cables, unsure why the outer sleeve on one is a lot bigger.:
(https://i.vgy.me/2SK8Zq.jpg)

Got the rear axle up in the air, wheels off, undid the cables at the calipers, then moved onto the removing the cables from the guide tubes and managed to shear both tubes - Nice!:
(https://i.vgy.me/xmXrgk.jpg)
One looks like it had been replaced - zero grease or lubricant in the tube

I have just tucked the cables into the stumps of the tube and will have to roll without a handbrake till I source replacement tubes.
Plus I was peering at the brake hardlines at the rear axle and they are looking a lot more corroded under their outer covers, so it looks like I will be dropping the tank again to fit cunifer pipes.
Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: LC5F on June 05, 2022, 09:56:21 pm
Moved onto the Alloy passat hubs, I surprised myself by not damaging the rubber boots on track rod ends and control arm.
One of the control arm ball joints let go with such force it knocked over one of the wife potted plants... oh well!

Went to put the Mk7 R caliper/carrier on and offered up the bolt and found I had forgot to to order the 55mm bolts required for alloy hubs - £6 pound a pop for genuine 10.9 ones on ebay, found alternative ones with higher tensile at 12.9, but only £1.50 each...the rub is its a pack of 10 and £4 postage - still cheaper than the other ones and I get spares too.
Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: JoshB on June 07, 2022, 06:05:53 am
When you said you looked on eBay for bolts, was it that VagBolts seller or whatever the name is?
I nearly bought some from him a few years back and thought they seemed a tad expensive, wanted new caliper bolts all round, so rung my local dealer and they were a lot cheaper!
Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: terrier on June 07, 2022, 06:18:00 am
 These 353911791312 :happy2:
Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: SANDEGTI on June 08, 2022, 01:20:20 pm
Absolutely incredible work, makes me want to go hands on with our GTI after being afraid of messing with it with little experience. Thoroughly enjoyed the read so far.
Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: LC5F on June 08, 2022, 07:51:33 pm
When you said you looked on eBay for bolts, was it that VagBolts seller or whatever the name is?
I nearly bought some from him a few years back and thought they seemed a tad expensive, wanted new caliper bolts all round, so rung my local dealer and they were a lot cheaper!

Yes - it was Vagbolts at £6 a pop, but the other ones arrived today...if it stops raining tomorrow I may venture out.

These 353911791312 :happy2:
Thanks fella - but its the M14 front ones I needed -but I currently have used ones of those supporting the calipers

Absolutely incredible work, makes me want to go hands on with our GTI after being afraid of messing with it with little experience. Thoroughly enjoyed the read so far.

Thanks - decades ago after really bad experiences with mechanics overcharging and/or poor work, I started on this mechanical quest, just started doing more and more stuff, building up skills and also the tools.
Get a haines and dive in!



Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: pudding on June 09, 2022, 12:32:08 pm
Good work!

I don't remember needing an alignment after fitting the Passat hubs, but probably worth getting it checked.

Yes, VAG-Bolts are definitely more expensive than the dealer for bolts!  I suppose it suits the folk who can't be bothered to drive to a dealer, and then go through the usual blank looks when explaining what parts you want, and then being told it'll be 3 days, or is on back order  :grin:

I can now agree with you about the 18mm bolts holding the turbo heatshield on, plus the additional 3 Torx.  What the actual??!  :grin:   I can see a strange kind of irony there about how over engineered the MK5's heatshield and airbox are, but on the MK8, it's what the under engineered engine cover falls off onto, and catches fire :grin:

Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: LC5F on June 09, 2022, 06:30:47 pm
Perfect 2 car driveway?
(https://i.vgy.me/ch1Mkv.jpg)
Front lip scraped on the way in and on the way out of the driveway.

Well it stopped raining... after work finished it only took 40 minutes to installed the new bolts and adjusted tie rods

I don't remember needing an alignment after fitting the Passat hubs, but probably worth getting it checked.
I suspect you may have changed tie rod ends to the longer passat ones - this is how mine was sitting:
(https://i.vgy.me/72UAal.jpg)

11 turns of the rusty moog tie rod on each side and its now toe in a bit:
(https://i.vgy.me/OOl9Mz.jpg)

Yes, VAG-Bolts are definitely more expensive than the dealer for bolts!  I suppose it suits the folk who can't be bothered to drive to a dealer, and then go through the usual blank looks when explaining what parts you want, and then being told it'll be 3 days, or is on back order  :grin:
I like my TPS and luckily they like me, but they can be a bit awkward to get some parts such as nuts & bolts - so if I can find non-genuine ones I tend to go there - plus sometimes other solutions show up during the search
Interestingly, I did order the H brake guide tubes this week, latvian ebayer who lists a lot of genuine stuff listed the tubes at £20 a side free postage...TPS £8 each.

I can now agree with you about the 18mm bolts holding the turbo heatshield on, plus the additional 3 Torx.  What the actual??!  :grin:   I can see a strange kind of irony there about how over engineered the MK5's heatshield and airbox are, but on the MK8, it's what the under engineered engine cover falls off onto, and catches fire :grin:
At least you were for-warned! - it was bloody confusing - did I read new turbo didn't solve the sluggishness in your ED30?

Booby prize:
(https://i.vgy.me/VARVDr.jpg)

More expense!
Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: pudding on June 10, 2022, 11:37:29 am
Can't see the pics at work but with the Passat hubs, it was literally just a case of swapping them over. No other changes. It drove just as straight afterwards as it did prior  :smiley:  Not saying that was right though as I might have overlooked something, but it's been fine for 5 odd years like that now.

The turbo did actually solve a few things in the end.  I was a bit premature with my judgement  :grin: 

Can't believe it was fitted 1000 miles ago already but the oil burning smells in traffic and the little puffs of blue have gone away.  Bottom end power/response is back to how it should be.  That was another clue the turbo was tired actually.  My GFB DV+ stopped doing it's little mouse squeak thing when lifting off the gas at part throttle, but now its back to full squeak mode.  The original may not have been ultra dead, but it wasn't far off, so it was worth doing  :happy2:

Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: RBS on June 14, 2022, 02:04:52 pm
Still looking good :happy2:  crap for the tyre and rim but nothing that can’t be fixed :wink:
Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: LC5F on June 23, 2022, 10:07:21 pm
Well -
I got the tracking done over a week ago, the nearest 4 wheel alignment place is Kwik fit over the hill, I have a pre-paid alignment package in place costing £150 that I thought I had 3x 4 wheel alignments in 2 years, already used 2, this time being the last. I thought I may have gone over the time limit...
When the guy called, I nervously asked if there was a charge... he said no, asking how long I had left, he said the package runs out in September and I still had 8 alignments left(!) - I am really confused, not sure what was going on with the deal I got - shame the steering wheel is slightly out!

Any way, I have been enjoying that new front wheel bearing feeling - everything is smooth, it seems to be taking a lot less effort, hopefully a slight MPG improvement - it's a joy to be in

One oddity about the passat hubs is they seem to be shorter than the Gti cast iron ones, previously I had a good 20mm clearance tyre to arch with occasional rubbage, now its dropped at least 5 to 10mm and rubbing a lot more + catching undertray on speed bumps.
Before the alignment, I tried to lift the coilovers up but the stupid 3mm locking grub screw, that I was not too cleverly used thread-locked to seal the top of the thread... just rounded out...heat & penetrating fluid didn't do anything apart from flames -  so currently I am even more static!
Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: pudding on June 27, 2022, 06:40:55 pm
Yeah B6 Passats are wider track than the GTI. I only got rubbage with the VWR suspension kit though, which was soft and low.
Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: LC5F on July 02, 2022, 04:30:30 pm
Yeah B6 Passats are wider track than the GTI. I only got rubbage with the VWR suspension kit though, which was soft and low.

Oh! - are they stretching the driveshafts out? - TT r32 contr4ol arms probably are not helping - still think there is some drop with the hubs, at least my scientific finger measuring says so!
front wing offside inner lip of has been caught.

Plus after the new handbrake cables, my rear calipers are sticking - had smoke coming out of the offside rear and warm alloy...local short duties till I get them sorted - hopefully, this will be the spur to get the black powder-coated ones built up.
Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: pudding on July 04, 2022, 03:54:48 pm
Yeah B6 Passats are wider track than the GTI. I only got rubbage with the VWR suspension kit though, which was soft and low.

Oh! - are they stretching the driveshafts out? - TT r32 contr4ol arms probably are not helping - still think there is some drop with the hubs, at least my scientific finger measuring says so!
front wing offside inner lip of has been caught.

Plus after the new handbrake cables, my rear calipers are sticking - had smoke coming out of the offside rear and warm alloy...local short duties till I get them sorted - hopefully, this will be the spur to get the black powder-coated ones built up.

I don't think so but you've got me thinking now.  I do get some wheel scrabbling on full lock, which I thought was just Ackerman hop, but hmmmmm..... :thinking:  Other than that, it drives normal.....I think. It's been so long since I've driven a standard GTI.

Passat hubs seemed to all the rage some years ago, but I think a few things might have been left out of the discussion  :grin:
Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: LC5F on August 07, 2022, 01:34:41 pm
So I finally managed to rebuild my powder coated rear calipers.
I moaned before about the what the company did - I wont be using again did by not blocking up openings/threads - the bores had been blasted and rough, so these needed honing. The threads for the brake line and bleed were also messed up - they were very close to being scrap.
The tubes in the carriers for Sliders, they managed to powder coat just inside these too, had to use a drill to clean this out - got all this shizzle out:
(https://i.vgy.me/T0fLNr.jpg)

What I had screwed up on my previous attempt was the circlip holding the handbrake mechanism into the caliper body, they are tricky as the tool need to have both the reach and fine tips. The only ones I have - or even could find - turned out they would foul on the inner handbrake mechanism. This was  stopping the circlip getting to the groove by about 3-4mm.  The only solution was to modify them to clear by filling them down:
(https://i.vgy.me/4buCid.jpg)

Plus the mechanism stands proud, so it has to pushed into the body, I came up with this G clamp arrangement amongst the mess of my bench - no wonder I cant find the sliders!:
(https://i.vgy.me/SiQGIY.jpg)

So after all this effort, with new sliders (gave up the search), cunifer pipe & brass fittings - the reward is this:
(https://i.vgy.me/2piLpT.jpg)

Hopefully I will get round to swapping these out soon, but need to prioritise the rusty spots over these.

The Golf still has some parasitic drain, someone posted ignition switch was possible culprit and there was a revised part, so swapped it out for a £13 Topran one - will see if there is any change, starting is pretty lazy after a few days parked up.
Opened up the old one, looks like its had some heat damage:
(https://i.vgy.me/2mvZjs.jpg)
Title: Re: LC5F's Graphite Blue GTI - Fun with Handbrake
Post by: LC5F on October 20, 2022, 02:31:47 pm
Been a bit pee-peed off with the Mk5...

So I finally managed to rebuild my powder coated rear calipers.
I moaned before about the what the company did - I wont be using again did by not blocking up openings/threads - the bores had been blasted and rough, so these needed honing. The threads for the brake line and bleed were also messed up - they were very close to being scrap.

I for-shadowed myself - I now have 2x Gloss black paperweights!

Looming MOT, Known issues:
Slice in NSF tyre - replaced front tyres for PS4 - now have them all round, very impressed, a lot stiffer than the rainsports.
Sticking Rear offside caliper - luckily I have replacements to hand.... or so I thought.

Swapped out carriers and calipers and got this great result:
(https://i.vgy.me/avIWrQ.jpg)

But when it came to bleeding the fluid just pissed out of the piston....better still, due to breeze and the angle of drive & jacked-up rear...I left the brake fluid can on top of the engine, the bonnet closed and I now have a dent pushing out that is very noticeable - Feck!

So the plan was re-install the good nearside caliper and find a reconditioned genuine caliper for the off side.
The received item had new piston and dust seal, but the hand brake arm seal is old and painted over:
(https://i.vgy.me/sxD6lZ.jpg)

All installed hopefully won't need to revisit brakes till warmer weather returns, I can replace the split seal with one from the paperweights.

On a positive - Work sent me to Berlin last week, suspect Hertz were low on cars - after cryptic questions such as "can you drive an automatic?" and "ever driven an electric car?" the ladies at Hertz were very generous and gave me this to drive for 2.5 days:
(https://i.vgy.me/Zzvh3m.jpg)

It took me 3 minutes to work out how to unlock the door with the credit card, and maybe another 8 minutes to get the thing to drive!
Thankfully, despite being in German the sat nav was good and got me to site.
Some you-tubing and I changed the language to English and learnt how to switch on the cruise - but couldn't get auto-pilot to work

Driving in Germany was ace! - Roads all billiard table smooth tarmac...on the autobahn, everyone in general was well behaved, very little lane hogging, and so many trucks all in the slow lane all doing the same speed, leaving 2 lanes clear
I just makes coming back to UK a real shock


Title: Re: LC5F's Graphite Blue GTI - F'ing Rear Caliper!
Post by: Clarkj93 on October 20, 2022, 02:52:19 pm
I bought these after mine were siezed earlier this year. https://www.ebay.co.uk/itm/164425013666

Not perfect, a bit too generous on the powder coating and the outer edge of some threads got coated but after a little sanding and threading the bolts in and out a few times it was fine with no leaks. If I could get better next time I would but for just over 100 quid it was a decent purchase and solved the issue I had.

Nice rental! Berlin is probably one of my favourite cities, and yeah driving around Germany is a pleasure, its more of a case of watching the road and using common sense  than worrying about getting a ticket and over aggressive drivers making your life unnecessarily difficult. The every 15 minute toilet rest stops are a great addition as well.
Title: Re: LC5F's Graphite Blue GTI - F'ing Rear Caliper!
Post by: LC5F on October 23, 2022, 09:59:45 pm
I bought these after mine were siezed earlier this year. https://www.ebay.co.uk/itm/164425013666

Not perfect, a bit too generous on the powder coating and the outer edge of some threads got coated but after a little sanding and threading the bolts in and out a few times it was fine with no leaks. If I could get better next time I would but for just over 100 quid it was a decent purchase and solved the issue I had.

Nice rental! Berlin is probably one of my favourite cities, and yeah driving around Germany is a pleasure, its more of a case of watching the road and using common sense  than worrying about getting a ticket and over aggressive drivers making your life unnecessarily difficult. The every 15 minute toilet rest stops are a great addition as well.

Cheers Fella - I was looking to match up my Mk7 R calipers in black - MOT tomorrow
Cant believe how poor UK roads are - spoilt myself in Berlin
Title: Re: LC5F's Graphite Blue GTI - F'ing Rear Caliper!
Post by: LC5F on October 24, 2022, 11:46:45 am
MOT result - Pass, no observations  :jumpmove:
Title: Re: LC5F's Graphite Blue GTI - F'ing Rear Caliper!
Post by: RBS on October 26, 2022, 05:43:42 pm
Well done!! :happy2: enjoyed to read all this :wink:
Keep up the good work :wink:
Title: Re: LC5F's Graphite Blue GTI - Pilgrimage to Caffeine & Machine
Post by: LC5F on December 06, 2022, 08:36:30 am
Cheers @RBS (https://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=11390)

Well, its the time of year when I make my trip to Wales - thankfully nobody tried to kill me on the M6 this year!
970 miles, not a single issue and very little oil used.

As I had all of last week off, and decided to visit more family in England - and also was near to Caffeine & Machine - so decided to make a pilgrimage

(https://i.vgy.me/ljWgfk.jpg)

Christmas tree:
(https://i.vgy.me/GT9iXi.jpg)
Door handle:
(https://i.vgy.me/1lFAVW.jpg)

Moto's to live your life by:
(https://i.vgy.me/BE7nV3.jpg)
(https://i.vgy.me/7IBJ8c.jpg)
(https://i.vgy.me/hEWMBA.jpg)
(https://i.vgy.me/XjttRm.jpg)

Sadly there wasn't really a good selection of machinery present on a grey Friday at 2pm, but the art on sale was good - staff were lovely and (as expected) the coffee was great too - a good way to burn an hour
(https://i.vgy.me/yJAe12.jpg)

Only random thing I found on my trip was a burnt out disco I spotted while waiting at traffic lights in Hereford:
(https://i.vgy.me/8k6M8v.jpg)


Title: Re: LC5F's Graphite Blue GTI - F'ing Rear Caliper!
Post by: GilesWoodward59 on December 07, 2022, 08:16:53 pm
Always worth popping into C&M for a pit stop. Particularly if it’s part of a Fossway blast 👍