MK5 Golf GTI
All Things Mk5 => Members Rides => Topic started by: Pesky jones on November 30, 2016, 02:50:42 pm
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Seat Leon FR 2008 DSG in black
As it stands
K04 turbo
K04 injectors
200bar sensor
rs4 valve
3 bar MAP sensor
Ramair CAI
Turbo back decat exhaust
Aftermarket large intercooler
HPFP re-built VIS stage 1 internals
NGK BKR7EIX spark plugs
Genuine R8 coil packs
Air-con delete
KW coilovers
Eibach anti roll bars front & back
Full custom welded roll cage
Sparco sprint seats
Willians 5 point harness
Need to sort out the fuelling and then take it to r-tech for a decent map. Hopefully all in time for the summer! Thanks to @Dan_FR (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=9513) for taking time to help and answer questions!
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ftriellymtb%2FMobile_Uploads%2FIMG_20161112_143339_zpsccepehfv.jpg&hash=3f2508ef4f437a5fd26af2004cfc1c5a56dbd4ac)
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Just been doing a few basics, getting it ready for summer.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fb558%2Ftriellymtb%2FIMG_20161117_161435_zpstnjyoncu.jpg&hash=f97fec561c8da61d2987f9b45173d146990de007)
Oil and filter, bought cheap oil to run for 200ish miles before swapping to millers. New fuel filter, NGK-BKR7EIX spark plugs, cam follower, HPFP and pick-up pipe o-rings, sump sealant and a new dipstick as the little orange ball about half way had disappeared from the disptick... I was reunited with it later on.
Took the sump off to see if anything was in it and to clean it as well as the pick up pipe. To clean it I used kitchen towel first to get most of it clean, then a bit of white spirit, with an old microfibre last. Also made a prison shank to use as a scraper on the burnt residue.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ftriellymtb%2FMobile_Uploads%2FIMG_20161129_144956_zpsam3wxkaw.jpg&hash=2e592c558207a9e19595b4e664a53e00946521d4)
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And there's the little orange ball.
The old follower was pretty beat up, looks like its never been changed. Cam lobe looks and feels OK through the cam chain cover though. Hopefully its a Rev B inlet camshaft with the tougher two-piece lobe. I know some BWA engines come with Rev A inlet. I wont know untill i either do the cam chain at some point, or could take the vacuum pump out and have a look.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fb558%2Ftriellymtb%2FIMG_20161117_163545_zpszhueq0tr.jpg&hash=171d4adbb00397ffbba3ffb2d4f1bfe3d93b3c7b)
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Nice Leon buddy, looks like it's being well looked after.
What's the part number for the sump sealant you have there?
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Very nice car with good specs so far :happy2:
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Any pics of he interior dude? Who did your cage?
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More than welcome mate :drinking:
Getting the essentials out of the way early - best way to start TFSI ownership. :happy2:
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Nice Leon buddy, looks like it's being well looked after.
What's the part number for the sump sealant you have there?
SD176404A2 Thanks, thats the plan.
Very nice car with good specs so far :happy2:
Cheers just needs a little more hardware
Any pics of he interior dude? Who did your cage?
I do but need to upload them, will get them up soon. Previous owner fitted it, somewhere in bury st edmonds from memory
More than welcome mate :drinking:
Getting the essentials out of the way early - best way to start TFSI ownership. :happy2:
:happy2: :drinking:
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Didn't even realise you got rid of the golf bro?.
Yeah whack some hardware on and you'll be laughing :grin:
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So I've done a bit of work on the car recently
New r8 coil packs to solve a misfire at high RPM - luckily the packs were the issue
Removed the bonnet sound deadening. Bizarrely, the previous owner deemed the front plastic wheel arches too heavy and removed them (although they actually serve a purpose in as much as protecting engine components (air filter, ECU etc.) from water/grit, but also the aerodynamics of the car) but didn't remove sound deadening. So anyway I removed the deadening which presented another problem. With the scuttle panel arrangement on the leon mk2, water can make its way through and drip onto the engine. Not so much of a problem if you have sound deadening as it just soaks it up and becomes mouldy, or if you have the stock engine cover as it protects the engine from the water. However, as I run an aftermarket induction kit I needed to address the issue before water started dripping through and onto my coil packs. (as a side note - I think the previous packs may have failed from this issue, even with the deadening - as the previous packs showed rust on them) The solution was to remove the scuttle panel and run a thin line of beading along the bottom, as well as filling in the holes. It seems to have worked as I don't seem to find any damp areas on the valve cover/coil pack area and when I pull the packs they are not rusty.
I also bought front arch liners from a guy breaking his leon and fitted them. No more muddy/gritty engine bay
I have also started looking at the hardware required for my stage 3 :wink: mapping at r-tech. Currently the car is mapped to the 2 bar MAP sensor, stock HPFP stock injectors, stock fpv and stock rail pressure sensor. And its a bad map as well, so the hardware needs to go in, and the map needs to come off.
I bought VIS internals for the HPFP as I have heard positive reviews. I re-built the pump with the VIS internals in the weekend just gone, it was a strange but not too demanding process. I am yet to put the pump back in the car so fingers crossed it has all gone right!
I have also bought the RS4 fuel pressure valve and the 3 bar map sensor. So I still need S3 injectors and the 200bar fuel rail pressure sensor. However, once I have those two, technically I can only install the FPV as the others need to be installed at the time of mapping. And seeing as the only thing I can fit before mapping is the FPV, which needs the inlet manifold off, I might as well wait for the injectors and do it all at once. Also want to give the valves a good clean when the manifold comes off. Im not sure yet whether i'll attempt this myself at home, and send my ECU to Nikki for a base map, or whether to get R-tech to do it all at the time of mapping.
So fingers crossed I might just get it ready for early summer for some decent track time!
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Getting there :happy2:
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So I've done a bit of work on the car recently
New r8 coil packs to solve a misfire at high RPM - luckily the packs were the issue
Removed the bonnet sound deadening. Bizarrely, the previous owner deemed the front plastic wheel arches too heavy and removed them (although they actually serve a purpose in as much as protecting engine components (air filter, ECU etc.) from water/grit, but also the aerodynamics of the car) but didn't remove sound deadening. So anyway I removed the deadening which presented another problem. With the scuttle panel arrangement on the leon mk2, water can make its way through and drip onto the engine. Not so much of a problem if you have sound deadening as it just soaks it up and becomes mouldy, or if you have the stock engine cover as it protects the engine from the water. However, as I run an aftermarket induction kit I needed to address the issue before water started dripping through and onto my coil packs. (as a side note - I think the previous packs may have failed from this issue, even with the deadening - as the previous packs showed rust on them) The solution was to remove the scuttle panel and run a thin line of beading along the bottom, as well as filling in the holes. It seems to have worked as I don't seem to find any damp areas on the valve cover/coil pack area and when I pull the packs they are not rusty.
I also bought front arch liners from a guy breaking his leon and fitted them. No more muddy/gritty engine bay
I have also started looking at the hardware required for my stage 3 :wink: mapping at r-tech. Currently the car is mapped to the 2 bar MAP sensor, stock HPFP stock injectors, stock fpv and stock rail pressure sensor. And its a bad map as well, so the hardware needs to go in, and the map needs to come off.
I bought VIS internals for the HPFP as I have heard positive reviews. I re-built the pump with the VIS internals in the weekend just gone, it was a strange but not too demanding process. I am yet to put the pump back in the car so fingers crossed it has all gone right!
I have also bought the RS4 fuel pressure valve and the 3 bar map sensor. So I still need S3 injectors and the 200bar fuel rail pressure sensor. However, once I have those two, technically I can only install the FPV as the others need to be installed at the time of mapping. And seeing as the only thing I can fit before mapping is the FPV, which needs the inlet manifold off, I might as well wait for the injectors and do it all at once. Also want to give the valves a good clean when the manifold comes off. Im not sure yet whether i'll attempt this myself at home, and send my ECU to Nikki for a base map, or whether to get R-tech to do it all at the time of mapping.
So fingers crossed I might just get it ready for early summer for some decent track time!
Hi Tom,
If i've read this thread correctly, your Ko4 converted already? Then no need for S3 injectors as you will already have them :confused: @Pesky jones (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=17818)
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Cage pics! :party:
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Hi Tom,
If i've read this thread correctly, your Ko4 converted already? Then no need for S3 injectors as you will already have them :confused: @Pesky jones (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=17818)
Sadly not. Half arsed conversion by previous owner - K04 turbo, K03 injectors, some sort of map that isn't very good. Will be a totally different car with 2+ hardware and some R-Tech magic
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What Dan said. He's very kindly being helping me through logging, interpreting the data, explaining how it all works and what it means so knows the ins and outs of the car :happy2:
Fitted the pump with new and improved internals back on tonight and been out in it for a few runs/logs. What a difference, it actually holds pressure all the way! Starting to get a taste of what its capable of now. As Dan says, once the injectors and associated k04 sensors go in, and Nikki gets his hands on it, it should be quite fun :)
Mike - here are some pictures - I don't have many mate! I think you may have already seen them on the fb group? Although, the cage itself is coming out unfortunately. I'm not confident in the welds, the bends in the tubes + seeing as I drive it on the roads a bit as well I think its for the best. For now, a harness bar will be going in so I can still run bucket seats & harnesses. Although long term plan is a welded rear only half cage when funds allow.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fah27%2Ftfsitom%2F16473707_10158144199580032_549674948171804325_n_zps5negrn6o.jpg&hash=0b2c20cf77dd8a47f54afd1244c507b404817438)
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Hi Tom,
If i've read this thread correctly, your Ko4 converted already? Then no need for S3 injectors as you will already have them :confused: @Pesky jones (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=17818)
Sadly not. Half arsed conversion by previous owner - K04 turbo, K03 injectors, some sort of map that isn't very good. Will be a totally different car with 2+ hardware and some R-Tech magic
That's nuts :mad: Good luck with it Tom, you'll be a happy camper indeed when Nikki gets his hands on it :evilgrin: :driver:
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Indeed. Chatted in FB, thought I recognised it. I should have known as there aren't many caged Leon's!
Sounds like a sensible plan
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Thanks guys - slowly but surely. Yeah the map is sh1t. After looking at logs from last night with Dan we come to the conclusion that it looks like a k03 stage 2 map has been uploaded which is just madness. Nowhere near enough fuel for the K04 and as a result there is loads of air/boost and nowhere near the required fuelling.
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How noisy is it with the sound deadening removed?
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Do you mean the bonnet deadening that I talked about in the previous post or the whole car? It is noisy, but not too bad if you're pootling about. Personally I love how much you can hear at full chat.
Where are you in the country, I could show you if close?
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Can you record a video?
I think a full cage is a bit much unless its on track more than road. getting in and out to go to test must be a pain lol
Rear cage ftw in you can.
OR
Just say F it and go full on track car :)
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Yeah Ill do a video.
To be honest when I bought it the intention was to use it on track more than road and I was just going to drive my girlfriends on the road when needed. I don’t need to drive it at all on the roads really – I live close enough so walk to work etc. and when I do have to drive it the roll cage really doesn't bother me - its not hard to climb into etc. BUT… now I want to drive it on the road more and especially will in summer, and although I have proper bought proper padding for the cage, it is still not properly safe without a helmet. So yeah I think it’s going to have to go. Rear cage at some point but just the harness bar for now.
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Im Nottingham buddy. I meant the interior sound deadening. I did away with the sagging bonnet deadening years ago :happy2:
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Pile of stuff to go in is growing. Should get the dsg oil, the engine oil and hopefully the anti lift kit in this weekend.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fah27%2Ftfsitom%2FIMG_20170307_234752_zps1vkjquhe.jpg&hash=7666b5e9882d4a9d8e46e1ceb601c23e6cfd8de0)
Miller's nanodrive nt+
New filter and o ring
ECS magnetic sump plug and washer
DSG oil, filter and washer
Powerflex anti lift kit
Rs4 fuel valve
3 bar MAP sensor
New k04 injectors
Fuel filter
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Got the miller's oil, magnetic sump plug and filter in today as well as carrying out the dsg fluid and filter service. Wasn't too bad, hardest bit was getting the car level in the air so the stack pipe let the right amount of oil out once refilled etc. Bought a funnel and tube all in one which worked perfectly, link -
https://www.amazon.co.uk/Draper-26327-Oil-Funnel-Tube/dp/B00BWR7B3Y/ref=sr_1_3?ie=UTF8&qid=1489409910&sr=8-3&keywords=draper+funnel (https://www.amazon.co.uk/Draper-26327-Oil-Funnel-Tube/dp/B00BWR7B3Y/ref=sr_1_3?ie=UTF8&qid=1489409910&sr=8-3&keywords=draper+funnel)
Sadly run out of time to try and get the anti lift kit fitted so will do that another time.
Now that's everything done in prep for the rtech visit. Just need to save enough for the stage3 and DSG custom mapping!
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You're going to love the car once the anti lift kit is fitted as I've done mine and it's wicked less lift more power :driver:
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You're going to love the car once the anti lift kit is fitted as I've done mine and it's wicked less lift more power :driver:
Yeah I need to get it fitted tbh. Looks fairly simple...apart from that passeneger side front bushing bolt. Did you completely remove the gearbox mount @r5gtt (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=11199) and did you jack directly under the gearbox itself to raise it? Were both front wheels in the air? Any tips for this?
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You're going to love the car once the anti lift kit is fitted as I've done mine and it's wicked less lift more power :driver:
Yeah I need to get it fitted tbh. Looks fairly simple...apart from that passeneger side front bushing bolt. Did you completely remove the gearbox mount @r5gtt (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=11199) and did you jack directly under the gearbox itself to raise it? Were both front wheels in the air? Any tips for this?
Got an MOT done yesterday. Passed with no advisories which is great considering the decat etc. :evilgrin:
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yeah that bolts a nuisance tbh but not a long job to remove battery tray unless you have a stupid air filter shield fitted :doh:
You need to move the black wiring harness out of the way toward engine to access three of the 16mm bolts and then pry it barward to access the last one. Leave the mount to engine three on. You will need to raise fairly high and better to have the both wheels up or even better all four innit a ramp so engine doesn't move and you struggle to put the mount back in.
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As the current map on the ECU didnt seem to account for the turbo that had been put on to it, it ran lean - k03 injectors, sensors etc. So having bought all the fuelling hardware plus a few extras for the k04 it was time to send the ECU to R-tech to load a k04 base map on to it. To unplug the ECU from the connectors you need to remove the bracket which is held by four anti-tamper bolts (2 smaller and 2 larger). To remove them you need to cut a slit in the head of the AT bolts to get a screwdriver into.
(https://c1.staticflickr.com/5/4016/34946364414_1cdde69c64_z.jpg)
Whilst the ECU was away, the k04 injectors, rs4 valve, 200bar fuel rail pressure sensor and 3 bar MAP sensor had to be installed, so that when the ECU returned it would run correctly. I had already rebuilt the HPFP with VIS stage 1 internals which are required for running 130bar. As the manifold had to come off to install the hardware I might as well clean the valves as well as installing a runner flap delete kit from AKS. Manifold off:
(https://c1.staticflickr.com/5/4068/35398255090_b17498823d.jpg)
These were my valves at 62k. Probably be the same again in 15-20k! Perhaps a proper PCV delete and meth might help prevent build-up :evilgrin:
(https://c1.staticflickr.com/5/4104/35654453181_8303c7f15d_z.jpg)
Half way through cleaning, time consuming process. I used nylon brushes with a drill attachment, petrol and carbon cleaner. I used lakeland stove cleaner which is really strong stuff. You cant leave it in there for too long!
(https://c1.staticflickr.com/5/4049/34976300393_d7d30c8eb7_z.jpg)
Inlet manifold with RS4 valve, 200bar fuel pressure sensor, runner flap delete with new inlet manifold and throttle body gaskets.
(https://c1.staticflickr.com/5/4028/35786349725_3bd7a26ddb_z.jpg)
K04 injectors installed back in the cylinder head. I bought new injectors so the teflon seals, washer and the blue o-ring that sits in the fuel rail were present but I had to get the locator clips from AKS which come in an injector build kit.
(https://c1.staticflickr.com/5/4144/35398039760_33ba66af3f_z.jpg)
After putting it back together, I primed the fuel pump a number of times and turned the key a bit nervously! It all fired up ok and after a short drive appeared to be behaving well. After putting my foot down it all seemed great - big smile! And this is just the base map!! After logging I was pleased to see the engine is no longer running anywhere near as lean as it was on the previous map, with lambda now at 0.79 opposed to 0.9. Fuel pressure up to 130bar so the HPFP and injectors seem to be doing their jobs!
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Well, what a difference. She's an animal! Worth the wait... Now just have to save up some pennies for the full custom map! And bigger brakes needed @Dan_FR (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=9513) :happy2: Thanks to Dan for all the help along the way!
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Good to hear it's running properly now mate. I've got to get a k04 some day!
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Thanks mate. Im very glad its running nearly properly as well! Few little niggles. Main one being that the DSG map is still the previous sh*tty Uber tuning map, whereas the ECU now has the r-tech engine base map so they dont talk to each other very well. I can't wait for the DSG + full custom map!!
My girlfriend said Ive been in the car more in the last week then I have the entire time I owned it beforehand :grin: :grin:
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Glad its finally up and running and driving properly.... Lambda previously hit over 1 under full load.... silly stuff....
Worth it in the end though
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As the current map on the ECU didnt seem to account for the turbo that had been put on to it, it ran lean - k03 injectors, sensors etc. So having bought all the fuelling hardware plus a few extras for the k04 it was time to send the ECU to R-tech to load a k04 base map on to it. To unplug the ECU from the connectors you need to remove the bracket which is held by four anti-tamper bolts (2 smaller and 2 larger). To remove them you need to cut a slit in the head of the AT bolts to get a screwdriver into.
(https://c1.staticflickr.com/5/4016/34946364414_1cdde69c64_z.jpg)
Whilst the ECU was away, the k04 injectors, rs4 valve, 200bar fuel rail pressure sensor and 3 bar MAP sensor had to be installed, so that when the ECU returned it would run correctly. I had already rebuilt the HPFP with VIS stage 1 internals which are required for running 130bar. As the manifold had to come off to install the hardware I might as well clean the valves as well as installing a runner flap delete kit from AKS. Manifold off:
(https://c1.staticflickr.com/5/4068/35398255090_b17498823d.jpg)
These were my valves at 62k. Probably be the same again in 15-20k! Perhaps a proper PCV delete and meth might help prevent build-up :evilgrin:
(https://c1.staticflickr.com/5/4104/35654453181_8303c7f15d_z.jpg)
Half way through cleaning, time consuming process. I used nylon brushes with a drill attachment, petrol and carbon cleaner. I used lakeland stove cleaner which is really strong stuff. You cant leave it in there for too long!
(https://c1.staticflickr.com/5/4049/34976300393_d7d30c8eb7_z.jpg)
Inlet manifold with RS4 valve, 200bar fuel pressure sensor, runner flap delete with new inlet manifold and throttle body gaskets.
(https://c1.staticflickr.com/5/4028/35786349725_3bd7a26ddb_z.jpg)
K04 injectors installed back in the cylinder head. I bought new injectors so the teflon seals, washer and the blue o-ring that sits in the fuel rail were present but I had to get the locator clips from AKS which come in an injector build kit.
(https://c1.staticflickr.com/5/4144/35398039760_33ba66af3f_z.jpg)
After putting it back together, I primed the fuel pump a number of times and turned the key a bit nervously! It all fired up ok and after a short drive appeared to be behaving well. After putting my foot down it all seemed great - big smile! And this is just the base map!! After logging I was pleased to see the engine is no longer running anywhere near as lean as it was on the previous map, with lambda now at 0.79 opposed to 0.9. Fuel pressure up to 130bar so the HPFP and injectors seem to be doing their jobs!
youve been busy lol glad you've nearly got it to run properly and hopefully get it to run fully 100% even quicker :happy2:
I got a hammer and chisel to the mk6 golf ECU snap bolts a few days ago and it worked a treat :grin: