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Model specific boards => Golf mk4 => Golf mk4 gallery => Topic started by: th3_f15t on 27 March 2015, 20:43
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Evening all. Here's my little story to share with you all...
Mate of mine calls up and says:
"Mate of mine has a Golf V5 that he's going to scrap if no-one buys it off him. I know you love your Veedubs so thought you might be interested in taking it on and fixing it up." Challenge accepted.
Now I'm a Mk5 Golf fan boy, not too keen on the Mk4 if I'm honest but I had to at least look at the thing, right? Can’t let a good car get scrapped if it can be saved with some minor work.
“Oh, by the way, it’s got some running issues. The cooling fans don’t come on when it gets hot, so they’ve been hard wired to stay on the whole time.” Ah, right… Not a big drama.
Send me some photos of the car I said, so I could look it at least a little bit:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_01_zpsgcf47in9.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_01_zpsgcf47in9.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_02_zps884egwga.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_02_zps884egwga.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_03_zpsxux9hsvu.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_03_zpsxux9hsvu.jpg.html)
Just another Mk4 to me, but that engine is attractive. And the asking price is low enough that the gamble is worth the risk I thought to myself. So I went to have a look at it and came up with the following list of faults:
3 faults from my scanner (need to get the codes again, lost them from my scanning tool)
- Crank angle sensor (assume this is the same as a camshaft sensor)
- Something with the cooling system (shocker)
- Something with the ignition barrel
Brakes full of air
Cooling issues (as mentioned)
Drivers side lock needs replacing, can’t put the key in
Rear wiper arm missing and the motor doesn’t even work
Front bumper is in need of a respray, looks like it’s been shunted (maybe why the cooling doesn’t work?)
Passenger mirror has taken a hit and needs new casing, possibly whole unit (although it does work)
Damn good service
Paint work is not great, many spots of rust (only spots though) and scraps/marks
Normally I’d walk away when I see crank angle sensor issues, but the thing runs so sweet (despite several faults) although those brakes need serious attention! The calipers, pads and discs, although rusted solid, are all pretty good with life left on them so I think it’s air in the system from being sat for months on end.
The interior just needs a good clean and a few trim bits swapped for better condition ones, the rear seat that folds down is a bit dodgy so may need to repair/replace that as well, but everything work and it’s amazingly good condition, despite being filthy. And there’s enough change scattered about to pay for at least an oil filter!
Other good bits, it’s done just 95,000 miles and been carefully owned (apparently). The engine bay is proper tidy and it appears it has been treated well. Just became unloved once the faults appeared. The plan as it stands is to bring it back to it’s former glory then pass it onto someone who’ll either love it or take it to new levels. Unless I keep it as a track toy…
Any advice, hints or tips is more than welcome and requested!
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Bring it on, looking forward to see this progress
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The V5 isn't a particularly good engine, certainly not quick and pretty poor economy too. Crank sensor is a common problem, it's situated at the bottom right corner as you look into the bay on most cars. It's a right angled sender and the insulation breaks down at the bend. Shouldn't be too difficult to swap out for new. Have a look on the usual sites to see how much these go for, as by spending too much getting it up to scratch, you'll surpass the pretty low ceiling price I expect. Your call though, and good luck with whatever you decide.
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Cheers mate. I got the car pretty cheap and if I keep spending low it'll be worth it. If I spend just enough making it run and tidy it up I could get a good return.
Or I could swap the engine for a BAM unit and have some fun. Either way, the crank sensor is number 3 job, 1st is the brakes and 2nd is the cooling system. Max budget on sorting all these issues out is £75 really.
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So the crank angle sensor is no longer outputting a fault code, but it was intermittent anyway so I’ll monitor that. The other two faults that remain are:
01271 – Positioning Motor for Temperature Flap (V68) – static – Faulty
00849 – S-contact at ignition Starter Switch (D) – static – Undefined switch condition
First fault is most likely the reason that the cooling fans won’t come on when required, but think the radiator fan switch may also be defective so I’ll get it tested and replaced if required.
Second fault I’m a bit lost on and a bit scared to play with the ignition wiring but may be a loose wire or something. Anyone who can tell me more I’d be very grateful!
Add to this list that the boot lock also doesn't let you put the key in. Things are getting stupid with this Golf now but I'm revelling the Wheeler Dealer challenge. Once I get the major faults sorted, it'll be cosmetic tidy up on a super budget.
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Little update, could be the thermostat according to a handy uncle. Because the fans are wired to stay on the whole time, looks likely the previous owner had the wires pulled out and shorted together to crate a constant circuit so will replace the 'stat and bleed the brakes fully next week. Fingers crossed £35 and a days work sort it for MOT!
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boot lock will just be a case of slowly getting your key in there with plenty of plus gas or WD-40, just give it time.
can't believe people still do that with the fans...
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boot lock will just be a case of slowly getting your key in there with plenty of plus gas or WD-40, just give it time.
can't believe people still do that with the fans...
Sure that boot lock advice has been given to me about something else in life... :whistle: Thanks for the tips mate.
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boot lock will just be a case of slowly getting your key in there with plenty of plus gas or WD-40, just give it time.
can't believe people still do that with the fans...
Sure that boot lock advice has been given to me about something else in life... :whistle: Thanks for the tips mate.
yeah getting your head through the door without hurting your ears :laugh: :laugh:
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Lol...sorry..that made me chuckle :laugh:
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Starting to get parts ready to get this V5 back on the road. I’ve ordered a replacement master cylinder off eBay, a new one was £145! Might get a new set of seals and refurbish it fully before installing it. Also got a new set of filters (oil, air, pollen and fuel), some new spark plugs, oil and coolant so hopefully by the time I MOT it’ll of had a full service as well. Also bought a thermostat and new coolant reservoir as the current one is full of crap and just want to make things look new and shiny under the bay. Starting to wonder whether I may keep this V5 as a second run around…
Anyway, some pictures showing some of the other minor areas that need attention. But first, my two Golfs:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_04_zpsvt4rgkrj.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_04_zpsvt4rgkrj.jpg.html)
So, boot lock and handle are pretty rusted up:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_05_zpsd1l8nr90.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_05_zpsd1l8nr90.jpg.html)
Rear wiper motor is seized and missing the arm plus wiper:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_06_zpskitszcbh.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_06_zpskitszcbh.jpg.html)
Passenger wing mirror has been hit by something and needs replacing:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_07_zpsnllcocqx.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_07_zpsnllcocqx.jpg.html)
The front bumper looks like it’s been hit, cracked the paint and may explain the cooling issues:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_08_zpstq6r4pnk.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_08_zpstq6r4pnk.jpg.html)
So this week I plan to sort the cooling out and service it, then when my master cylinder arrives clean it up and refurb is possibly before installing it and bleeding the brakes through with completely fresh fluid. Discs and pads will be stripped off to inspect the calipers for any signs of failed seals as well, just to be safe. After that it’s just a damn good detail the car needs then an MOT. Provided it passes depends on what happens next with this car. If it fails I’ll put it into storage, sell the engine and turn it into a BAM engine track car. If anyone has any hints, tips or good how-to guides, comment away. I’m always happy for help!
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sell it get a 1.8t plenty of cheap 1s about :smiley:
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Yeah, that's what I'd likely do. Its just this one has good bodywork and low milage so the shell is a good one.
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Yeah, that's what I'd likely do. Its just this one has good bodywork and low milage so the shell is a good one.
mileage means nothing and the v5 engine is not easy to tune :whistle:
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I wouldn't tune a V5 even if I had the parts for free! Just wanted to save a good car from the scrap yard and make a few quid towards funding my mk5 GTI. As you rightly said, so many cheap mk4 1.8T about its fair better to pick up one of those for tuning. Have spotted one near me that looks abandoned so may offer a stupidly low price and pick it up as another project for restoration.
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Pictures and tiny progress. The engine bay itself:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_10_zpsk0vbqhq6.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_10_zpsk0vbqhq6.jpg.html)
Should look lovely once I clean everything up and service it. Although while trying to locate the ‘stat, I noticed this:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_09_zpsrqeff5cr.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_09_zpsrqeff5cr.jpg.html)
My thoughts are this is the “fix” someone did to get the cooling fans running, so I’ll need to re-solder the wires back together properly and basically repair the loom! Not what I was hoping to have to do, this project is quickly becoming a more and more complicated affair.
Only thing to cheer me up is this bit of service history that came with the car:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_11_zpsgv9mgzft.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_11_zpsgv9mgzft.jpg.html)
That, and 2 old MOT certificates is all I currently have for the car, but I’m going to chase the previous owner (who I’ve never actually met!) and see if there’s anything else lying about. Anyone who can shed light on what wires connect together please inform me or give me a diagram/picture so I can attempt to repair the loom.
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I made some small progress with the V5 today. Started draining the brake fluid ready to swap over the master cylinders, still waiting on the replacement part to arrive though. Also started stripping away the bits I need to in order to get at the ‘stat housing. Also gave it a good scrub yesterday to start getting the paint work back into some sort of decent condition:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_14_zpsgtfeplvr.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_14_zpsgtfeplvr.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_12_zpsmtfb7xyx.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_12_zpsmtfb7xyx.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_13_zpst36uyx0r.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_13_zpst36uyx0r.jpg.html)
However, as I was pulling the wiring connections of various things, I discovered that previous mechanics have been somewhat unkind to the connections. The mass airflow sensor is slightly damaged:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_16_zps3rdwtoux.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_16_zps3rdwtoux.jpg.html)
And the connection to the ignition pack thing (whatever its proper name is):
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_15_zpsifyfpnmq.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_15_zpsifyfpnmq.jpg.html)
These combined with the ‘stat sensor issue leave me with three options:
1) Repair the current loom, preferably removing it from the car (cheapest)
2) Replace the loom entirely with a replacement part, about £100 off eBay for one (preferred)
3) Replace the whole engine with a 20V unit (or the 1.8T 20V unit) (extreme)
I’ll most likely source a replacement loom in good condition as it’ll be far easier to just replace the whole thing. While I’m doing that, may as well strip off the inlet manifold and throttle body and give them a damn good clean up. Slow progress expected as time slips past me…
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Shortly after I wrote the last post, replacement master cylinder turned up. So gave it a quick inspection and clean up:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_17_zpsxgd6hlim.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_17_zpsxgd6hlim.jpg.html)
Out with the old:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_18_zpsdmrzpdud.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_18_zpsdmrzpdud.jpg.html)
In with the new:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_19_zpsby9gxwla.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_19_zpsby9gxwla.jpg.html)
Tomorrow, if I feel up to it, I'll put fresh fluid in and bleed the whole system including the clutch though to get all new fluid in there. Because I've ripped the coil pack and leads out, can't drive it to find out if it's solved the brake issue! Might also order the new 'stat housing and crack pipe soon too, as well as drain out the old coolant and prepare the engine for the new bits. Will probably replace the coolant sensor there at the same time as it's not something I want to do again in a hurry!
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Second day of brake restoration, started off rather well but went sour at the end. Borrowed a pressure bleeding tool to make the job a one man show, plus made sure that I had all the tools to do the job from the start. Turns out all you need for bleeding the whole brake system is a pressure bleeder kit, a waste bottle, 8mm and 11mm spanners and a jack. Don’t even need to take the wheels off (although it may help).
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_20_zpsrj3sheio.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_20_zpsrj3sheio.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_21_zpskofvd3us.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_21_zpskofvd3us.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_22_zps3pw06vjt.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_22_zps3pw06vjt.jpg.html)
The rears bled OK, did drivers side first, then passenger, when to do the front drivers side and the bloody bleed nipple was rusted and rounded off but the previous mechanics. Whoever worked on this car before really wasn’t a good mechanic, when I find out who it was I shall name and shame them publicly. Have a suspicion which garages it could be…
Anyway, options now are to remove the wheel for better access, clamp the line and try to replace the bleed nipple with a new one in situ, but chances are it’ll have to come off and go on the work bench. I’ve refurbished calipers before so it’ll be no hardship to remove both the fronts and give them a total rebuild and possibly a lick of paint for looks.
Also discovered coolant dripping out from under the engine when jacked up, traced it back up following the damp trail and surprise, surprise it was coming front the thermostat housing! At least this wasn’t another job adding to the list as I was doing that job anyway. Chances are I’ll postpone any more work on the car until I can get it towed and into a proper workshop to get it up on 4 axel stands and properly stripped down (bumpers off, wheels and suspension off, the lot!).
Stay tuned for project “Teeth Cutting” restoration updates now, the dream of “Wheeler Dealer” style is over as there’s no profit left now.
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In other news, ordered a new engine wiring loom for £133 delivered (was £153 but i offered lower) and a new set of front brakes for £51. The brakes are off a late model A3 so come painted black and the nice eBay seller said hell send the lowest mile pair he can find. Rather chuffed with that result.
Also got bored this evening so mocked up what red wheels and mirrors would look like:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_23_zps5kf1ipdr.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_23_zps5kf1ipdr.jpg.html)
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No pictures yet, but a good/bad day once again! Replacement brakes turned up from eBay and after being told by the seller that they would be checked and I was assured that all bolts would be tested to make sure they weren't seized before dispatch. Even said they'd find me a nice, low milage set.
Did they f**k!
So now it looks like I will have to do a complete re-build on the fronts, which means I've wasted £50 on something I didn't need as I could of just waited and pulled my current ones off the car. But still, means I can get them re-build and looking good while I'm waiting for workshop space to come about. Also, I have no locking wheel nut so I need to find one that fits from someone else to get the wheels off. Which is why I'm happy enough to have a second set of front calipers to work on while I wait!
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Well I thought I’d try and make a little progress with the V5 today, mainly focusing on the wiring loom which arrived this week:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_24_zpshfcmorbo.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_24_zpshfcmorbo.jpg.html)
Can’t be that hard if it’s in such a small box, right?
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_25_zpsjlpm7ipx.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_25_zpsjlpm7ipx.jpg.html)
Bugger. Still, can’t be too hard as the connections only go in one location each and only reach certain points in the bay so easy enough to work out. I started by laying to new loom out to mimic the position of the engine bay by location each connection, starting with the end of the loom itself. Got about 3 connections in before I spotted a problem. Look as the new loom and you’ll see there’s 2 connections quite close (about 40cm) from the start of the loom:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_26_zpslt9yaoy4.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_26_zpslt9yaoy4.jpg.html)
But looking at the same part of the loom which is in my engine bay and that connection is actually about 100cm away from the start, it’s out of shot but you can see the connections leading off in the bottom right of this image:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_27_zps28vccfbh.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_27_zps28vccfbh.jpg.html)
All other connections seem to be in the right place and correct for this engine bay, just got to figure out why there’s a slight difference. Starting to wonder if the eBay seller listed it for my engine but it’s actually for the V5 20 valve 170bhp engine…
In other news, the locking wheel nut is missing which means my wheels are stuck on for now. Decided to see if I could use a spline tool bit to crack the locking wheel nuts off to allow progress anyway. Before continuing on, spot the missing thing in this picture:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_28_zps5kaetdrl.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_28_zps5kaetdrl.jpg.html)
It’s missing a locking bolt completely! And on inspecting the other 3 wheels, the locking nuts are not even finger tight, so thankfully I can remove the wheels and get on with the brakes when it gets into the workshop next month. Just go to source a new set of locking nuts with tool bit now! On the subject of brakes, the eBay seller apologies for sending me crap items and is sending me another set for free which, I’m assured again, will be personally checked by the guy I messaged to make sure they’re fit for purpose. Now I’ll have two sets of 288mm front brakes, which I’ll refurbish myself and hopefully sell for a little money back. Whether I’ll have discs and pads for each spare set remains to be seen, would be nice though.
So now I need to investigate the wiring loom issue along with waiting for a decent set of front brakes to arrive. Also sourced a set of BBS Montreal 2 16 inch alloy wheels for £50 which are half way through a refurbishment so will finish them myself to keep costs down (unless I plan to keep the car, then they’ll get powder coated gloss red with the calipers). I’ve not bought any new items for the V5 yet as waiting to get it into a workshop and really assess the state of the engine. If it looks like it’ll need even more work than it currently does now, I’ll upgrade the engine to something with 20 valves. Whether it’ll be a 1.8 litre turbo lump or 2.3 V5 again, unsure…
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So I had almost lost hope on the current V5 engine and had begun researching the possibility of putting a 2.8 litre V6 from the 4motion into this car, teemed with a 6 speed manual gearbox from a GTI and the possibility of using an R32 stainless steel exhaust system mixed with the 4motion cat back to create a mk4 VR6 so to speak. I’m still looking into it and may well do that at a later date, building the engine up from the bare blocks for a laugh.
However, I managed to source a replacement engine loom from a local breakers yard, been to visually inspect it in the car it’s in now and it looks like a good one so getting it removed from the donor car this week and will go back to collect it when it’s ready next weekend. Also, the car is getting trailered tomorrow to my new workshop where I can really get cracking. I thought I was hiring just a plain floor space but it turns out I’ve hired a workshop bay that has a ramp, shot blaster, presses and industrial air compressors, so basically everything is available to me now so this is definitely turning into a built not bought project! Also, while in the breakers yard I picked up a replacement wing mirror and rear wiper motor plus arm:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_30_zpsi6kmqulk.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_30_zpsi6kmqulk.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_31_zpsxhsiuys1.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_31_zpsxhsiuys1.jpg.html)
Later revision motor I believe, which is a winner. Last weekend I also managed to strip down the replacement calipers completely:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_29_zpsgsj2kvs7.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_29_zpsgsj2kvs7.jpg.html)
Also have a second set and the ones on the car, so I plan to strip them all down, paint them all black or red, rebuild with new seals and bleed nipples then sell two sets on to recover some costs and put a replacement set back onto the car. Also I may strip of the rear brakes and rebuild then fully too, seems stupid to put all this effort into the brakes to leave them as they are.
So the short term plan is to get the car back on the road for use while I overhaul my mk5 GTI. I still need to replace the thermostat housing and coolant pipe, tempted to put the ECS Tuning metal pipe in as it seems replacement V5 pipes are about £30 and the ECS Tuning is only £55 and will outlast the car. Also, get the replacement wiring loom in, inlet manifold painted (for a laugh) and a full service (including changing the gearbox oil) and then an MOT. Provided it gets back on the road straight away and ready for duties, the longer term plan will be to completely redo the interior (ICE, new trim, Bora illuminated vents, possibly some nice seats but giving no clues away!), possible the engine swapped mentioned at the beginning of this post and maybe air ride (don’t hate me). Depends how much spare cash I have after the mk5 GTI has been worked on, but at least time and space are no longer an issue. Stay tuned, and as always, feedback or comments always welcome.
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Got the car trailered away to the workshop today, but discovered a nice little puddle of water in the passenger foot well this morning:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_32_zpshepbwtgj.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_32_zpshepbwtgj.jpg.html)
Another problem to investigate when I get through the other jobs. But it’s in and jacked up on stands, finally:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_33_zpspirijdrh.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_33_zpspirijdrh.jpg.html)
Decided to get one with pulling the front brakes off to get them all sorted and finished so I can sign off the braking fault. Naturally, things went wrong. Passenger side disc screw is completely buggered so going to have to drill it out or weld a bolt onto it and wrench it free. Also, someone’s done a poor job of repairing the wires to a broken pad wear sensor. So need a new sensor and to re-do the rubbish wiring repair that is currently in place. Driver’s side dust shield, one of the bolts has rounded, ripped the rotten shield off like it was cardboard but need to get the bolt out as I may bother to put replacement shields in but personally don’t like them as the just cause issues in the long term. Currently looking a bit like this:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_34_zpsw7v1ujlt.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_34_zpsw7v1ujlt.jpg.html)
Bit tired and fed up of the car today, but I won’t be beaten. Just annoying that I could break the car now and make double what I paid for it, but for now I plan to keep at it and save it from the scrap heap. No updates now until next weekend. But I have ordered a new thermostat housing, cooling pipe and some paints along with picking up the new wiring loom next week. All the parts that I need are now sourced, that is until something else throws in the towel.
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So yesterday I got a little bit more work done. Managed to remove the last bolt left in the driver's side hub for the dust shield, I don't like them so they come off whenever I get a chance. So the driver's side is now all but stripped completely for new brakes. Passenger side still has the disc on, need to drill the positioning screw off and then get the remains out using grips. Also stripped down a second set of front brakes ready for refurbishment:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_35_zpsq3zrnffg.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_35_zpsq3zrnffg.jpg.html)
While working around, I noticed the passenger wheel arch liner was damaged, so out that came along with the remains of the damaged under engine covers:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_36_zps9pqh4h8z.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_36_zps9pqh4h8z.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_37_zpswfcorhuu.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_37_zpswfcorhuu.jpg.html)
Found a nice build up of mud in the front wheel arch! Needless to say, I shall now strip of the drivers side and clean up under there too:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_38_zpsjiyhm0uq.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_38_zpsjiyhm0uq.jpg.html)
I made a good go at shot blasting the first set of front calipers down, but after 6 hours of blasting and 2 hours of being locked out the workshop, I didn't get them completed! Going to purchase myself a nice power drill, wire brush set and maybe some acid cleaner to completely strip them to bare metal and smooth ready for spray painting bright red. I will get some pictures next weekend of the brakes, but I also need to invest in a tool cabinet and top box, power tools, work bench and various other tools and supplies to build my work space up. Things are getting serious now in terms of work space!
If anyone has any suggestions to good little suspension mods other than a set of decent lowering springs, please let me know. I've heard R32 wishbone bushes are a good, cost effective little mod to improve handling a bit? Not looking to break the bank, about £250 on suspension is the budget. Maybe more if I sell some refurbished calipers for profit.
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Another weekend, another round of problems arise to challenge this "quick fix" project. Decided to remove the front end completely as it'll make life far easier to replace the wiring loom, clean the inlet up and replace the coolant housing and pipe work plus the thermostat and sensors. Immediately discovered yet more poor workmanship of previous "mechanics" (term used very loosely):
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_39_zpsyfmqx4y1.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_39_zpsyfmqx4y1.jpg.html)
So out came the damaged driver's side wheel arch lining, not as much mud as the passenger side but still worrying amounts of build up:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_40_zpsqw4a9fsy.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_40_zpsqw4a9fsy.jpg.html)
Off comes the front bumper to add to the pile of bits destined for the skip:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_43_zpss4i8u4bc.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_43_zpss4i8u4bc.jpg.html)
But during taking off the bumper:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_41_zps7fyf5ldd.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_41_zps7fyf5ldd.jpg.html)
Yes, one of the big ass bolts has sheared completely in two, so the body of the bolt is well and truly stuck inside the main frame that it's all bolted too. Not overly bothered, but my options are try and drill it out from the other side once the front end is off the car, or drill it from the side on show, but maybe I'll visit the scrap yard again and just get a whole new metal frame and start again from scratch, seeing as I'm headed to the scrap yard again next week. More on that in a bit...
So anyway, decided that rather than plough on with doing the coolant housing (after spilling half the coolant on the floor when draining it),thought I'd attack the brake disc that's stuck on. Plan was to drill the head off and use grips to pull the threaded shaft left behind out. Easy, right?
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_44_zpspzytr0nw.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_44_zpspzytr0nw.jpg.html)
Another drilling job. May look at taking the hub apart as if I was changing wheel bearings (may even just replace them while I'm here!) and then drill that bolt out as well. Or get a replacement part from the scrap yard.
A final note, the engine management wiring loom I had won't fix the hacked wires that short the fans out to stay on the whole time, the cooling system appears to have it's own loom so I need to get that from the scrap yard as well. So my list currently looks like this:
Replacement cooling system wiring loom
Both arch liners
Under engine covers
Possibly new frame for radiator
Possibly new parts to hub
Another productive day.
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Seems to be one step forward, 2 steps back on this project mate, but keep at it, you'll get there in the end! Plus once you're done at least you'll know its been done right, dread to think what bodges there are on my Octavia, best not to look too closely :P
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In short:
http://www.ebay.co.uk/itm/191574376611?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Happy now.
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So I've got this week off work and spent the last 4 days over the workshop making some progress with the V5 by taking more things apart. I swear one day I'll write an update about putting something back on the car. Anyway, starting with the brakes and suspension as a whole, things have gone with the theme of the car and a simple fix or inspection resulted in needing all new parts! But first, some shots of the refurbishment of the front brakes:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_45_zpsonbng0kb.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_45_zpsonbng0kb.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_46_zpsgx6gsy2k.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_46_zpsgx6gsy2k.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_47_zpskrihktqe.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_47_zpskrihktqe.jpg.html)
They're currently getting their top coats of bright red at the moment, but a second set have been sent to the powder coating place I use to get their treatment and whichever set looks better I'll use on the car and sell the other set of eBay to get some money back. I plan to get a cheap set of 256mm vented rears on the car now at this stage, eventually I may put on some 334mm 2 piston fronts as well for some loveliness but depends how I feel about adding weight to the wheels. 334mm brakes would also require a set of 17 inch alloys too, I don't plan on 18 inch as I want to retain ride comfort.
On the note of ride comfort, discovered that the driver's side hub has about 1mm of play so safe to say that the wheel bearings are naff and require replacing as well. £66 on eBay later:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_49_zpsv9k89j97.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_49_zpsv9k89j97.jpg.html)
Thought I could be cleaver and pull the hub out without dismantling everything. Turns out I shouldn't try and be clever at this stage:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_48_zpsos9wlaeh.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_48_zpsos9wlaeh.jpg.html)
What I've gone and done right there is damage the CV joint a little bit. So I'll also replace those items as well as ball joints as it'd be rude not to while the hubs are dismantled. I am toying with the idea of poly-bushing everything and fitting anti roll bars too at this stage as it'll be a perfect time what with over half the major work of dismantling the front suspension done to do the hubs and bearings. I looked at the cost and can get all the bushes and roll bars up front for under £300 and I reckon a weekend of work should sort it. I've already cracked all the nuts off ready to swap the hubs, nothing rounded which was amazing. Soaking it in WD40 the night before really paid off, a lesson learned right there!
In engine news, as you may of seen in the previous post, the current V5 engine has been deemed beyond saving and a replacement V5 sourced and delivered this afternoon:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_50_zpsd8bwpaqi.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_50_zpsd8bwpaqi.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_51_zps50a5rp27.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_51_zps50a5rp27.jpg.html)
Ordered an AQN 170bhp engine and gearbox instead, for a little better economy and performance. It'll be the main engine until I get a V6 sorted, but needed to accelerate the project and it makes more sense to just swap the whole lot. I have one issue to sort with the new engine and that is that they cut a few wires from the battery which feed off to the cooling fans and systems so will have to splice in my existing ones but everything else looks perfectly in tact, no cut pipes or butchered ends. Not a bad little find, it's covered just 69K miles according to the advert and I have the clocks and ECU to prove this as well.
So that's it for now sadly, preparations for an engine swap are under way and the suspension and braking repairs/upgrades are on hold until it's done, I fancy only one major job at a time to be honest! And I haven't even done anything to the car back from the front wheels so who knows what other major jobs I'll uncover later on! Stay tuned folks...
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dude iv never actually owned mk4 golf (Cpl of mk1 leons lol) so not sure why I read the whole of your thread!
but good look and I hope it gets sorted.
My other love atm is a 1990 sapphire 2000e. restored over winter. so I spotted cossie looks pretty tidy. yours?
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No, it belongs to the guy who I rent my workshop space off of. We fired it up for the first time in a year the other day, only took a few turns of the engine to fire up and it sounded amazing. Worth a bomb too so very careful when I'm working around the workshop near it!
Currently researching how to convert a throttle cable to fly-by-wire so if anyone's got and advice that'd be grand.
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Right, it's been a hectic few weeks what with deciding to sell off my mk5 GTI and replace it with a mk6 Golf R. I won't go into details here why I've chosen to do this but in essence I can't handle 2 project cars on the scale I was planning the mk5 GTI and what this mk4 V5 has escalated into. I'm really sad to have to part ways with the mk5 GTI but it has to be done unless cheap storage comes up local to me back in Essex. But anyway, back to the V5. Well, after a 3 day turn around the calipers that I dropped off at the powder coaters came back and they look amazing! Here's a shot comparing my painting skills against the powder coaters skills:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_52_zpsh5ghqi4o.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_52_zpsh5ghqi4o.jpg.html)
Needless to say they are epically good and only cost me £84 for both calipers! Just need to rebuild them and I have a (basically) brand new set of front 288mm brakes. Started cleaning the pistons and slider pins:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_53_zps77hcymlc.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_53_zps77hcymlc.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_54_zpsvtnwjhlu.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_54_zpsvtnwjhlu.jpg.html)
I didn't take pictures of the lot finished but I've done 2 calipers worth of pistons and pins as I'll build both sets up and sell the painted ones on to someone else who'll use them lovingly. But I now plan to get my wishbones and hub structure all powder coated in the same red too, just because it's something different and you don't see many people doing it. May even do the wheel arch linings too, for extra giggles. Speaking of painting and plastic parts:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_55_zps7oqijsfs.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_55_zps7oqijsfs.jpg.html)
R32 replica, here we come! Just need some side skirts and possibly a spoiler now, although may leave it off to mix the look up a little bit. Also plan to remove the "Golf" and "V5" badges but leave the emblem and handle to give a sort of smooth look to the rear, while teaming a mesh style grill with the R32 front bumper and some other little touches. Naturally, you've probably guessed by now that I'm going all-out on this V5 now to make it my little show car. Not aiming to be famous or in magazines, but just going to have a little fun building something I would love to see at a show and drive daily. I don't know how quickly thing will progress this next few weeks as I'm all over the shop but hoping to get at least one weekend put aside to sort the engine swap out. Stay tuned...
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You'd be right, I found that forum when looking for how-to guides so I kept it going on there as well for extra pointers. I love my mk5 GTI but she's up for sale now as I'm moving on to a mk6 Golf R.
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Spent a few more hours in the workshop this weekend, decided it was time to put something back together rather than always taking something apart! Got on with rebuilding the brakes that I had powder coated as they look so much better than my hand painted ones. Putting in new seals isn't an easy job:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_56_zpskjnnqisl.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_56_zpskjnnqisl.jpg.html)
Then pistons:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_57_zps7bsaglrn.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_57_zps7bsaglrn.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_58_zpsfwgf2rsb.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_58_zpsfwgf2rsb.jpg.html)
New bleed nipples and protective seal:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_59_zpsnoopdy7l.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_59_zpsnoopdy7l.jpg.html)
And re-using the almost new Pagid brake pads I got:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_60_zpshlh5zhjz.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_60_zpshlh5zhjz.jpg.html)
Would of cost £200 to have them refurbished for me, I spent half that on brand new seals and getting them powder coated. All in it's about 4 hours of not rushed work but would probably take me less than that again now I've got the experience up. True test of time will be when they're bolted to the car and bled I guess so I'll report back how effective my savings were then.
Would of attacked more of the engine swap by the workshop was literally full of photocopiers so I could hardly move. Even getting to the work bench to do the brakes was a nightmare but hoping over the month of July to make some head way with getting the new V5 into the engine bay.
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Another quick bit of work on the V5 this weekend, the workshop is a state still so plans have been stalled in terms of getting the new engine fitted and running. If it carries on I'll suspend the swap and focus on the front suspension for a time. But got it a little more stripped down and ready:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_61_zpsdtlaguby.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_61_zpsdtlaguby.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_62_zps6ybxx7nt.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_62_zps6ybxx7nt.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_63_zpsoilayeks.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_63_zpsoilayeks.jpg.html)
I was going to replace the radiator while I was going through all this, but it's fairly new as it is (it's not a OE part, but a Valeo) so it's been replaced within the past few years so that's a bit of good luck for once!
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_64_zpsyh5bpmwr.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_64_zpsyh5bpmwr.jpg.html)
Just got to sort this out now:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_65_zpsxhqc5hou.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_65_zpsxhqc5hou.jpg.html)
Will drill out the stubborn bolts and try to go back to keeping costs right down on this car, as I need to heavily save after picking up a replacement for the mk5 GTI last week,
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Been slow progress lately. I say slow, I really mean none. I've been focused on selling the mk5 GTI so that's stolen all my attention. But I did do one thing today:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_66_zpsewmr9zxj.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_66_zpsewmr9zxj.jpg.html)
Spun it round ready for the engine swap. Hopefully in the next month it'll be running again, but may need another wiring loom (not the main engine one though) as I might of cut through some wires today while removing the outer casing of the loom. Sad times...
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So for the first time in over a month I've spent some proper time working on the V5 today, quite literally! Spent all day getting preparations for the removal of the current engine made but going through all the wiring. It's a pretty big job but I've now got a rough plan of what I'm going to do. But first, here's some pictures, as it helps explain my progress better:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_67_zpszmkso4z3.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_67_zpszmkso4z3.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_68_zpsnq3frgzd.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_68_zpsnq3frgzd.jpg.html)
So as you may be able to see, I've sorted out a lot of the wiring (probably about half the total wiring), figured where most things are that I need to replace but have yet to convert the throttle pedal to a fly-by-wire set up. What I've discovered, is the main engine loom (not the engine management one) is itself in 2 parts, and both of these are damaged on both my engines! So what I may well do is take a trip to a scrap yard, ask them very nicely to essentially de-wire an entire V5 170bhp Golf and just take all the wiring looms that I require and replace the lot rather than attempt to repair the ones I've got. I've got to take effectively 2 MASSIVE looms and splice them together, taking the working parts of each loom. I may attempt this, and that way I can hybrid the new loom with my existing loom to ensure there aren't any issues when putting it all back together. The main wiring area of concern is this part:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_69_zpsrfvok4yv.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_69_zpsrfvok4yv.jpg.html)
If I can extract this from the car, it'll be a perfect opportunity to try some loom repairing, mainly for a laugh. But this loom is LONG, is goes from the bottom of the radiator, includes all the battery wiring, wiring to the alternator, up through the bay and into the bulkhead, all along the wind screen, then some goes back into the engine bay under the fuel connection points to the other side of the radiator while some snakes off down the bulkhead and to connections into the cabin, and some passes through the wing into the bonnet. Needless to say, it's a tough job but I'm quite excited about getting it done to be honest, will be a huge lesson learned once complete.
So the reason for the delay is I've had a lot of personal problems to deal with over the past month, along with selling my mk5 GTI (still for sale by the way) and getting my mk6 Golf R and focusing on that, I'd forgotten just how much fun this little mk4 V5 actually was. Messing with engines and cars is what makes me feel happy so I'm glad I'm on an extended weekend off work to relax and what better way that to rip this car apart!
Currently working out a plan now, as the original desire to get this car up and running so I could work on the mk5 GTI is now gone, thus if it sits about for months unfinished it's no drama. So I think I may go all-out on it now and get it up to a semi show-going level (no intention of entering it in competitions, just want something pretty). May smooth the bay a little bit, hide some of the wiring and colour scheme things for fun.
Also, sourced some OZ alloy wheels, a Recaro leather interior minus door cards (re-trim in plans so not bothered), front anniversary lights, rear USA lights and a few other bits and bobs too that I can use. Basically taking someone's left over mk4 parts collection so I can use them all on my project. Because that's now what it is, a full on "go hard or go home" kind of thing.
Plus it saves my Golf R from being messed with... Too much.
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You may of read the very last line of the previous post which was "Plus is saves my Golf R from being messed with... Too much". Famous last words...
I've been very focused on my other Golfs of late, plus with work being really busy and various other excuses, I've achieved next to nothing over the past 2-3 months. But today I finally started making some progress again, by which I mean I took more things off. I've moved bays in the workshop now so I have more light and space which is a massive bonus, but before that, now I think about it, I did manage to strip the air conditioning system right down a few weeks ago but today I did some further prep work for the engine removal:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_70_zpse3gnipcn.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_70_zpse3gnipcn.jpg.html)
From here it's just the connections to the power steering and rack, drive shafts and gear linkage that all need to be full removed then it's out with the old and in with the new... Yeah, about that. Decided to start preparing that for going in and in usual style, started by taking things off:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_71_zpszlmgbisl.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_71_zpszlmgbisl.jpg.html)
It's been cut as well, decided that I'm going to get all replacement looms from the scrap yard and just have non-cut apart looms and re-do the whole lot. I'll also scrub down and possibly re-paint/smooth the engine bay a little bit just to tidy up but not going to show queen level! After taking the wiring off the alternator I had to move a component out the way:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_72_zpsjcp1xyg1.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_72_zpsjcp1xyg1.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_73_zpskmq04lvu.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_73_zpskmq04lvu.jpg.html)
The infamous "crack" pipe. Seems like a good time now to replace it and the thermostat housing as I have the parts and the engine is out the car so it's so easy to work on compared to when it's in the car seems a crime not to do it now. I also plan to do the axillary belt and some service parts as well before installing the engine as it just seems the most sensible use of time right now.
I've yet to free up money and pick up the previously mentioned items but I haven't abandoned them. I had toyed with the idea of scrapping this car and getting an Impreza STI but then I remembered the point of this build is mostly to learn everything I need to know at a basic level to build something a little bit more powerful. Mind you, it's already proved its value when I did the intercooler swap on the Golf R as well as a few other jobs.
Rest of this week is focused on getting the old engine out, strip it of any parts worth selling and scrap the rest. Its beyond saving as there's corrosion inside the head somewhere and I can't be bothered to pull the head off just to see if it's worth saving properly. Hopefully the pace may pick up a little again now the major plans for the Golf R are done.
Famous last words again perhaps..?
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Well, progress has been slow to say the least, but this isn't a dead in the water, abandoned project! I've been focusing my efforts on the Golf R but a lot of the work for now is done on that until I save some serious cash for the interior re-trim. So, what's been happening these past 6-7 weeks since I last updated..? Well, firstly I've officially written the old V5 off as it's beyond saving...
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_074_zpsuapkzsrf.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_074_zpsuapkzsrf.jpg.html)
Inside the cylinder head is corroded so it's no longer worth salvaging, even to make a few quid back. I'll rip it apart completely just to get my hand in engine building a little bit, as if I break anything on this engine its no real loss at all. So now that I'm going full steam ahead with the engine swap, I decided to start preparing the replacement engine and getting it up to my standard. Replaced the coolant pipe and thermostat housing along with a new sensor and 'stat plus all seals and gaskets. Should stop any more leaks for a long time!
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_075_zps3w6theul.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_075_zps3w6theul.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_076_zps2sxwvt2d.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_076_zps2sxwvt2d.jpg.html)
Everything was cleaned up too so it's looking rather lovely now. Also stripped off the old remains of the exhaust manifold:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_077_zpsztmci9tp.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_077_zpsztmci9tp.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_078_zpsuezs1n9d.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_078_zpsuezs1n9d.jpg.html)
Now I've got an axillary belt arriving this week and spark plugs to gap, filters to add in and a general once over of everything else (all electrical connections and a clean up) and then it's good to go. Sadly, I discovered some other issues with the car that will need addressing. First one is that I want to re-use the exhaust in the short term just to get it running till I can get a custom on made for my R32 replica rear bumper, however getting to 3 off the 6 bolts is a nightmare! I can see why the salvage yard that supplied my replacement engine just cut it after the intersection of the two pipes.
My other issue is that while unbolting the drive shafts I noticed that the inner CV boot cover on the driver's side is failing and the lubricant from inside is all over the place so the chances are it's knackered out. I think I'll get some replacement drive shafts, new inner and outer CV joint kits and remove the sub frame for powder coating as well as the wishbones, hubs and all the other bits. Seeing as I'll have the bay stripped it'll be far easier to do the sub frame and roll bar/front suspension while it's all apart.
I need to visit a scrap yard still to acquire some other bits, mainly a whole engine bay wiring loom! As well as front wheel arch guards, interior parts and a replacement bonnet and passenger wing... Things are getting there but very slowly!
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I've managed to get some serious hours into the V5 this weekend, been working on preparing the new V5 170 engine for going into the engine bay, it now has all the coolant and thermostat weak areas addressed, new oil filter, plugs and axillary belt:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_079_zpso2hvj9ey.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_079_zpso2hvj9ey.jpg.html)
Finally, after many, many months, I broke out the engine crane:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_080_zpsqryz4nfk.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_080_zpsqryz4nfk.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_081_zps8x1hybwr.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_081_zps8x1hybwr.jpg.html)
It's now officially down and out the car! Milestone reached, there's no going back now:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_082_zpsap1vimlw.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_082_zpsap1vimlw.jpg.html)
Began tearing the rest of the wiring loom out, discovered that one bit of it doesn't need to be replaced which was a result, just the main one that needs swapping. It's a mission as it goes everywhere and into the bulkhead, need to find where it separates from the interior loom so I can pull the whole thing out, take it to the scrappy to get a replacement and then wire it back in. Currently looks like this, all disconnected apart from the bulkhead:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_083_zpsqgtuteqe.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_083_zpsqgtuteqe.jpg.html)
Onto stripping the old V5 down and salvaging anything worth restoring and selling on as spare parts:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_084_zpsmnypxi7s.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_084_zpsmnypxi7s.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_085_zpswxm1qwpb.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_085_zpswxm1qwpb.jpg.html)
As I left it today:
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_086_zpsinq8zftt.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_086_zpsinq8zftt.jpg.html)
(http://i687.photobucket.com/albums/vv235/mikemaher205/Mk4%20Golf%20V5/Mk4_V5_087_zpsmmaz39ig.jpg) (http://s687.photobucket.com/user/mikemaher205/media/Mk4%20Golf%20V5/Mk4_V5_087_zpsmmaz39ig.jpg.html)
Think I can re-condition and sell on the alternator, power steering pump, air conditioning compressor, cam angle sensor, throttle body, ECU and the stock air box. Even if I only get a few quid (literally) I'd be happier with that than throwing away parts that work. Sadly the engine itself is beyond saving, so many snapped bolts, broken connections and internal corrosion, but still loads of useful information gained by ripping it down to the blocks. Will break it further and at least try and sell the gearbox as that may be of use to someone.
Unlikely I'll do much more now for a few weeks but you never know, I'm highly motivated at the moment to get things progressed and back onto some sort of decent schedule. I have been toying with scrapping it and working on my R32 but decided to carry on for now and go as far as I can without spending much more and assess in a few months time...