Luke's GTI Build Thread - Update June 2018

[lukemk5gti]

I'll whatsapp you there now and see if we can diagnose the thermostat!

[r5gtt]

Update - 03/04/2017 - PCV Breather Hose, Door Lock Switch & Inline Thermostat Replacement

Finally got a good day so I tackled the following:

PCV Breather Hose - 06F 103 235
The long corrugated pipe for the PCV. I had only changed my PCV a few months back but never got around to changing the longer pipe (part number - 06F 103 235)

Unless your hands are that of a child I recommend getting a needle nose pliers in there and just cutting the connection on the old pipe.

While I was there I cleaned the carbon from the connection. You can see just how much built up here:


Inline Thermostat
Then I tackled the inline thermostat, I had competed my main thermostat two years ago. Since my car is manual I only have the two.

Symptoms for main thermostat - doesn't reach 90deg unless sitting in traffic. Immediately drops when you start to cruise again.
Symptoms for inline thermostat - car takes any longer than 10 mins to get to 90deg

I found my car wouldn't reach 90 after a 30 mile trip sometimes so thanks to @Pesky jones I picked up an inline thermostat along with this pliers which you 100% need to tackle the mole clips on the thermostat

https://www.aliexpress.com/item/Auto-Vehicle-Tools-Cable-Type-Flexible-Wire-Long-Reach-Hose-Clamp-Pliers-for-Car-Repairs-Hose/32669094950.html?spm=2114.01010208.3.1.lME9iG&ws_ab_test=searchweb0_0,searchweb201602_4_10065_10130_10068_10136_10137_10138_10060_10062_10141_10056_10055_10054_10059_10099_10103_10102_10096_10148_10052_10053_10050_10107_10142_10051_10143_10084_10083_10080_10082_10081_10110_10111_10112_10113_10114_130_10078_10079_10073_10070_10123_10124-10102,searchweb201603_4,afswitch_1,ppcSwitch_5,single_sort_0_default&btsid=0ad3ac63-1b09-4e37-94a6-e8532d09d9e5&algo_expid=969f2c9b-931a-447d-a7e2-fd026b57ad41-0&algo_pvid=969f2c9b-931a-447d-a7e2-fd026b57ad41

I jacked up the car, removed the plastic underbody protection and that gives you enough space to pop the old one out.


Then with a very strong hand I took off the thermostat and in the process ingested about 2L of coolant. I imagine the addition of coolant in my system will give me better performance.

Old vs new. Same part numbers.


I topped up my coolant but didn't drive it.
Wait 10 mins and turn it off and then top it up.
Then I started car and did a few metres and then topped up.
Finally I left it overnight before topping up.
When I got to work that morning it also needed another 100ml.

It seems strange that the coolant took so many attempts to fill the entire system.

Door Lock Switch

VW quoted me  €40 + vat for this but thanks to @fab5freddy I picked one up that he had lying around for €15.

Not much to this one:

Pop off handles and disconnect
Remove 2 x T30 torx behind handle
Remove 3 x T20 torx on bottom of door
Remove 1 x T20 torx on top left corner of door
Pop off door skin from bottom up. Do it in warm weather or clips might break
Remove 2 x T20 torx from inside door handle
Pop off door handle
Replace switch

Didn't think to take a photo while my door skin was off but since I was changing my gf's wing mirror I just by chance happened to have her door skin off so here's a photo of that

omgosh that pipe 

[lukemk5gti]

Tell me about it @r5gtt

I wouldn't mind but that was after I cracked the pipe off and cleared half of the carbon, beforehand it was about 70% coked.

My PCV has been changed twice now but that breather hose looks like it's been there for 10 years.

The car is 100% running smoother since changing it too!

[r5gtt]

Tell me about it @r5gtt

I wouldn't mind but that was after I cracked the pipe off and cleared half of the carbon, beforehand it was about 70% coked.

My PCV has been changed twice now but that breather hose looks like it's been there for 10 years.

The car is 100% running smoother since changing it too!

thats mental mate, maybe a good idea we all have a look down there as most likely have something blocking it up. Good job well done 

Weird thing I noticed when I had my door card off was no 3rd speaker in there next to the door handle or wiring harness for a speaker 

[Shoduchi]

(...)
Weird thing I noticed when I had my door card off was no 3rd speaker in the next to the door handle or wiring harness 

Lower spec'd Golfs only have 2 speakers in the door cards.

[dools225]

Tell me about it @r5gtt

I wouldn't mind but that was after I cracked the pipe off and cleared half of the carbon, beforehand it was about 70% coked.

My PCV has been changed twice now but that breather hose looks like it's been there for 10 years.

The car is 100% running smoother since changing it too!

thats mental mate, maybe a good idea we all have a look down there as most likely have something blocking it up. Good job well done 

Weird thing I noticed when I had my door card off was no 3rd speaker in the next to the door handle or wiring harness 

Mine hasn't even got rear speakers! I thought they were knackered at 1st so removed rear door card to find nothing 

[r5gtt]

(...)
Weird thing I noticed when I had my door card off was no 3rd speaker in the next to the door handle or wiring harness 

Lower spec'd Golfs only have 2 speakers in the door cards.

what a piece of chit  no wiring either   

[r5gtt]

Tell me about it @r5gtt

I wouldn't mind but that was after I cracked the pipe off and cleared half of the carbon, beforehand it was about 70% coked.

My PCV has been changed twice now but that breather hose looks like it's been there for 10 years.

The car is 100% running smoother since changing it too!

thats mental mate, maybe a good idea we all have a look down there as most likely have something blocking it up. Good job well done 

Weird thing I noticed when I had my door card off was no 3rd speaker in the next to the door handle or wiring harness 

Mine hasn't even got rear speakers! I thought they were knackered at 1st so removed rear door card to find nothing 

I know when I fade my stereo is goes to rears 
Stupid vag cars eh 

[lukemk5gti]

(...)
Weird thing I noticed when I had my door card off was no 3rd speaker in the next to the door handle or wiring harness 

Lower spec'd Golfs only have 2 speakers in the door cards.

Wasn't there an optional extra "10 speaker pack upgrade"?

I'm sure I remember running that code list on the sticker in the boot and the audio upgrade was an optional extra.

[Shoduchi]

(...)
Weird thing I noticed when I had my door card off was no 3rd speaker in the next to the door handle or wiring harness 

Lower spec'd Golfs only have 2 speakers in the door cards.

Wasn't there an optional extra "10 speaker pack upgrade"?

I'm sure I remember running that code list on the sticker in the boot and the audio upgrade was an optional extra.

Yeap, it was an optional extra. Higher spec'd Golfs had the 10 speakers from factory. In my country all GT Sport, GTI and R32 have them. There was also available the VW sound amplifier (VW Sound System) as an optional extra. Too expensive, for what I recall.

[lukemk5gti]

Yeap, it was an optional extra. Higher spec'd Golfs had the 10 speakers from factory. In my country all GT Sport, GTI and R32 have them. There was also available the VW sound amplifier (VW Sound System) as an optional extra. Too expensive, for what I recall.
[/quote]

You can buy the amplifier on eBay now for £120 or so, thread came up recently!

[Shoduchi]

You can buy the amplifier on eBay now for £120 or so, thread came up recently!

I'd prefer to get the full Dynaudio system (speakers and amplifier), since I have a RNS-510, or speakers from Hertz and good amplifier. At the moment I prefer spending my money on uprated parts for track use.

[lukemk5gti]

Update 24/04/2017 - Engine Flush, Dropped Oil Sump, Oil Pickup Pipe, Millers Nanodrive, Service, Mini Meet & DRL's

So I'm closing in on 100,000 miles and as preventative maintenance I decided to flush the engine using Wynn's engine cleaner followed by dropping the sump, cleaning the oil pickup pipe, changing the oil for Millers Nanodrive 5W-40 along with oil and air filters.


Firstly I added the full can of Wynns engine cleaner to the engine and left it idling for 20 mins to circulate. I then stopped the engine and put it on axle stands before stripping the underbody protection.


I then dropped the sump and inspected the gauze on the pickup pipe. A bit of blockage so I used a pinhole attachment on the pressure washer and blew it out along with cleaning down the sump itself. No need to replace the pickup pipe in my opinion. I then used a hair dryer to leave the entire thing bone dry. I followed it up with loctite heat resistant liquid gasket and threw it back on.




Finally I changed the oil filter and air filter for MANN filters from Micksgarage.com at a great price. I was stuck here as I didn't have a 36mm spanner but thanks to @ducman77 he sorted me out and even set the torque wrench to 26NM 


A full top up with Millers Nanodrive 5W-40 and I was back on the road.


A road covered in oil unfortunately  I had a great drip tray for the oil set up but forgot to account for the increase in flow when I removed the oil cap and so it shot out past the tray for a second.


I then bumped into a few like minded individuals for Ireland's first ever mini meet 


Finally I VCDS's the indicators as DRL's. Found they threw errors at 25% so I lowered to 10% and I'm looking good

[r5gtt]

I would never ever use engine flush on any of my cars as I've tried it once and never again  :doh:makes the car rattle like mad

[lukemk5gti]

I would never ever use engine flush on any of my cars as I've tried it once and never again  :doh:makes the car rattle like mad

You know what, I could hear a rattle afterwards that nearly sounded like the chain which I've never had an issue with.

I think it's gone now which leads me to believe it was just sucking all the oil up to every single crevice.

If I could go back I probably wouldn't use it but considering I dropped the sump and cleaned everything down I'm not afraid of any lasting issues.