Well this one goes like this..
Back in 2000 my dad bought this Golf GTI.. it was intended to be the last car he ever buys...
Fully loaded, leathers, climate, metallic black, 17inch santi monica Etc Etc/
He chose the dreaded 2.0 8v, bear in mind he got this car when the MK4 was relatively new out.
The 2.slow has lived up to its reputation of been sh!te.. he has always serviced the car on time and at the dealer.. at 80k it had to have a full engine rebuild due to a known fault with the pistons this engine suffers from (uses lots of oil, oil in the spark plugs....)
this was carried out at a specialist VW garage 3 years ago and i got all the parts needed from my contact at the dealer (at a cost of £640 with my discount!!)
well guess what... the exact same problem has returned
Current milage on the car is 127 000k
His options were to break the car
buy a new car
convert the 2.slow to something decent
i went with option 3.
i Sourced AUQ (same as the Mk4 Anniversary has) This one came from a yellow Seat Leon Cupra which had been in a light rear end.. the car drove spot on and i have the FSH for the car, HPI report, all old bills and even the MOT which runs out September 2012!!!
from the donor car i took the following for the conversion
Engine (covered 90k)
Full Looms
ECU
6 Speed gearbox
Gear linkage
Hydro pipes for 6 speed
6 speed Driveshafts
OEM side mount intercooler
DBW pedal and loom
airbox
all ancillaries etc
Cat / Downpipe / Turbo (K03s)
I had the Turbo inspected as it was passing a hell of a lot of oil
turns out the seals were all fooked so my mate gave it a full refurb, the fixing studs had also snapped off so they had to be drilled out!
he did a £400 job for mates rates (£70)
The engine had a nasty oil leak from the Half moon seal (common on 1.8T) so i got about degreasing the lump and fixing the leak
Replaced as follows:
(All genuine parts form the dealer)
Cam tensioner seals
Cam cover gaskets
Spark plug gaskets
Spart plugs
Oil pick up pipe
Sump Gasket
Gearbox oil
Engine oil (full synthetic)
oil filter
Air filter
Coolant
various pipes
Various gaskets
Various bolts
Secondary air pump piping
Waterpump
Cambelt
Aux belt
Clutch kit (3 part kit including slave cylinder)
MAP sensor
MAF sensor
DV (to be changed to forge)
I also fitted a Jetex exhaust, i sprsyed the flat part of the rear of the box black as it shows from behind the car on the mk4 and i wanted a factory feel to it (or as much factory as i could)
Anyhow here are various pics from the conversion
This took us 2 days to complete
How it all began
The Donor car:
The AUQ (after a massive amount of degreasing )
German engineering... Nice
another 8v off the road:
Another bay ready to be cleaned!!
Full engine undercover
OEM Intercooler located
AUQ meets its new home
Here is the part i painted black
The Turbo..
before refurb:
After refurb
New studs
shiny
All finished:
Going to go see Nick from Carbon for a cheeky Remap :-)
