Project: 2001 1.8T Golf IV

Discussion about automotive projects
Post Reply
User avatar
Rabbit Farmer
SCCV Board Advisor
SCCV Board Advisor
Posts: 5193
Joined: Wed Jun 25, 2003 11:37 pm
Location: Milton, Vermont
Contact:

Post by Rabbit Farmer »

Added video to the VermontRacing.com site for one of the track sessions with NEQclub.org at Lime Rock (June 2007).

83mb so right-click/save as HERE

The popping you hear is when the flame was shooting out the side exit exhaust. Nick, who was following in his STI, caught it on his in-car video also. ;)

Steve
Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar
User avatar
Rabbit Farmer
SCCV Board Advisor
SCCV Board Advisor
Posts: 5193
Joined: Wed Jun 25, 2003 11:37 pm
Location: Milton, Vermont
Contact:

Post by Rabbit Farmer »

Done. I might procrastinate, but I get things done (now, about that turbo single round headlight Rabbit I have been talking about for years....)

Anyway, a number of late nights and one weekend I was able to pull out the old engine, put together a new one (never opened the new engine.... should have only 40k miles). The whole process was not difficult, but it was time intensive. Surprisingly, everything went together... kinda intuitive. I did discover that almost all the parts on the NB engine (stuff bolted to head, valve cover, block) are different than the Golf. Right down to the hard metal coolant tube that runs along the front of the block (found that out after I install all the tubes, wires, etc.).

Anyway, some pictures for those of you bored with the text (I know I am).

Engine out (removed head and then lowered block/transmission out the bottom)
Image

New engine with everything bolted on, Spec clutch, flywheel, transmission installed, etc.
Image

How many 20-valves can you spot in 4 seconds? ...go!
Image

I removed the DP and both axles and was able to (quite easily) bring the completely assembled engine up through the bottom. I had thought the turbo being bolted to the engine would prove to be too big for the engine bay opening. Good news!
Image

Image

Every wonder why VW's have some electrical issues? This is what the wire looks like that went to the secondary air pump and power steering pump. The power steering pump wires were also broken off. Of course, the damage could have occurred when I removed the engine, but honestly I have no idea how that could have happened.
Image

I don't think that I need ANY of this. I already removed the secondary air pump from in front of the oil pan. Since I wasn't sure what I needed/didn't need and didn't have time to experiment, all the parts went back in.
Image

Location of 034 ECU and relay board. I took the time to remove all 034 EFI wires that ran along the driver's side (left side of car for those of you with the steering wheel on the incorrect side) and ran everything on the passenger side of the car. I took the ECU out of the rain tray, cut a hole through the fire wall with an air nibbler (love that tool!) and put the ECU where the passenger airbag was. In the future, I'll have to get it mounted better, but it will get me by for this season. No pictures of the changes yet, as I need some sleep.
Image

Heading to Moon Performance in NY at 2:00 on Thursday so that they can dyno tune the car to get it ready for Watkins Glen. Fingers are crossed that everything works.
Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar
User avatar
Rabbit Farmer
SCCV Board Advisor
SCCV Board Advisor
Posts: 5193
Joined: Wed Jun 25, 2003 11:37 pm
Location: Milton, Vermont
Contact:

Post by Rabbit Farmer »

Son-of-a-Fahvergnugen-hatch-backing-knuckle-cracking-hub-capping-no-compression-valves-making-noise-pain-in-my-butt!

Engine makes noise when it runs. I will be getting new rings in the mail on Tuesday and changing them Tuesday night. If there is an issue with the head (which it sounds like this is the issue), then I have a real problem as I don’t have any extra good heads to us. I have my $200 block/head setup, but that has bent valves and I have the old head that the pistons were throwing the rings against them at 6000+ rpms. I just might have to use that…

Picking up car from NY tonight. Bringing it back on Wednesday night assuming I have it together.

ACK! I am so sick of this crap!
Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar
User avatar
Rabbit Farmer
SCCV Board Advisor
SCCV Board Advisor
Posts: 5193
Joined: Wed Jun 25, 2003 11:37 pm
Location: Milton, Vermont
Contact:

Post by Rabbit Farmer »

More progress... bottom end is done. I just need a complete head and I should be done in about 3 hours. (that's 3 hours on Thursday night)

Anyway... tired so here are a few pictures.

New pistons and rods finally arrived. Since I didn't have them the other night when I knew that I had to rebuild, John at Fast Addiction was nice enough to next day up rings and a head gasket.
Image

Compared... notice the location of the top ring on each piston. The new piston is covered with assembly grease, hence the dirty look.
Image

The old pistons. For some reason that had dents (old dents!) in the pistons.
Image

Three in so far... notice the new EGT sensor. :)
Image

Bottom shot with hanging oil pump chain.
Image

And finally the last one going in. Pump back on, oil pan back on, etc. Done with this step. One more night and then it is a trip to NY.
Image
Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar
User avatar
Mr. Bridgestone
Posts: 1454
Joined: Sat Jun 26, 2004 12:21 am
Location: Milton, Vermont

Post by Mr. Bridgestone »

Steve. I feel your pain. Hope it all goes well. I asked Julie if you needed help, but I already knew the answer. Stay away. Sometimes it's easier to work on thing's yourself. :shock:
SCCV # 71
2016 Ford Fiesta ST / ARRIVED
2003 Mini Cooper S / SOLD
1990 Mazda Miata / Mariner Blue / SOLD
2005 Subaru Legacy GT Wagon / SOLD
P.C.R. Jaguar 80cc Shifter Kart / SOLD
User avatar
Rabbit Farmer
SCCV Board Advisor
SCCV Board Advisor
Posts: 5193
Joined: Wed Jun 25, 2003 11:37 pm
Location: Milton, Vermont
Contact:

Post by Rabbit Farmer »

Turns out the head I finally ended using was crap also. It dropped a valve inside the engine. It started and ran great... never sounded so good. Put it on the trailer at 6am (when I finally finished working on the car after an all nighter), took a shower (needed it!), drove to Moon in NY, started it (sounded great), it stalled, couldn't start it again. Tried starting it a number of times with the laptop hooked up to it to figure out what was going on and about the 6th time we heard a clunk. Took the plug out and the end of the plug was flat.... huh!?! Looked down the plug hole and we could see the face of an exhaust valve looking back at us. Thankfully the head failed during a starting instead of running action. So, the Golf isn't going to Watkins Glen and won't be rebuilt for a while as I plan to get a new head.. perhaps ported and polished and ready to bolt on. Hmmmm, maybe some new Cat cams while I'm at it. Snow will be flying before that happens, but I do plan on taking it apart sooner than later just to see what happened. Hopefully there was not damage to the new pistons.
Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar
User avatar
Mr. Bridgestone
Posts: 1454
Joined: Sat Jun 26, 2004 12:21 am
Location: Milton, Vermont

Post by Mr. Bridgestone »

And the hits just keep on coming huh?? Sorry to hear about that Steve.. :cry:
SCCV # 71
2016 Ford Fiesta ST / ARRIVED
2003 Mini Cooper S / SOLD
1990 Mazda Miata / Mariner Blue / SOLD
2005 Subaru Legacy GT Wagon / SOLD
P.C.R. Jaguar 80cc Shifter Kart / SOLD
User avatar
Rabbit Farmer
SCCV Board Advisor
SCCV Board Advisor
Posts: 5193
Joined: Wed Jun 25, 2003 11:37 pm
Location: Milton, Vermont
Contact:

Re: Project: 2001 1.8T Golf IV

Post by Rabbit Farmer »

------------- Project Update -------------

It is March 2008 which is the month I scheduled to start working on this car again for the next race reason (tax refund comes in the mail in March).

Plans:
Getting new head (naturally)
Kevlar cord timing belt
Perhaps getting rid of the coilpacks and going wired
Getting rid of OEM wires/tubes under the hood that aren't needed as I have stand-alone.
Electronic booster controller (controlled by 034EFI ECU)
Dyno tune with two maps (high HP and moderate for the rainy days)

That is it for March (I think).

Big brakes planned for later.

After running 100% with bigger brakes, I don't think I will be doing anything with the car for a while. I want to change the suspension to lower it more without changing the suspension geometry (read as "lowering the car with shorter springs or coilovers is not the best way to make a car handle"... I need re-engineering). For example, my other Rabbit (a 1980 Rabbit) is lowered in the front using heightened strut towers and modified mounting points for the front and rear spindles... the rear is independent suspension to boot!

Progress (and therefore photos) will start in a couple of weeks as I am busy right now shopping for parts and weighing options.

Steve

------------- Project Update -------------

I'm still waiting for my website to come back online, so for now, enjoy the little red x's.

------------- Project Update -------------

May, 27, 2008

Progress.... picked up a complete 1.8t engine with transmission.... unfortunately it is an automatic with front end damage. (free auto tranny to anyone who wants it... it is just weight at the scrap yard to me... want to practice working on auto transmissions? Here is your chance. But wait... order the FREE transmission now and get a free under the hood wiring harness.)

Picture of disassembling "new" engine... and taking stock wiring harness out of the car so just the 034EFI will be there plus the 6 or so stock wires needed for sensors, etc. I will be working very fast on this in the next couple of weeks as I have a track event on July 14, 2008 that the Golf would be better than the Rabbit (5 hours of driving at the event).

Image
Image
Image

------------- Project Update -------------

June 20, 2008

Progress.

Turbo/exhaust manifold is bolted to the new head. The broken valve damaged one of the pistons. I had two options: 1. get one piston and have it balanced to the weights of the other three, or 2. get a new set of pistons for now (JE pistions) and do the "get one piston to complete the set" for later engine builds. Anyway, new pistons will be here on Monday.

Right now I have all the pistons/rods out of the car waiting for the new pistons. Everything should be together by Saturday.

Now, time to work on the new Rabbit and the water pump on the Cabriolet. I need a vacation.

Steve

------------- Project Update -------------

June 27, 2008

Well, I have been away in MI for a week (Sun-Fri). New pistons were in this AM and I started installing them around 3:00 PM or so. I bolted the head on around 10PM and ran into a little snag (one with two solutions). The 5mm x 50mm stud that is needed to compress the timing belt tensioner is way too short when the tensioner is already fully extended (i.e. the belt is not longer on the car). I plan to head down to SAC in Williston on Saturday morning to get a 5mm x 70, 80, 90, 100 (hopefully they have it). I could get a bunch of 100mm and cut them down, but they should be cheap enough to just buy the different lengths.

Plans are to fire this up on Sunday..... Saturday is busy with a BBQ at our place so time is limited on Saturday.

Boring photos to follow on Saturday.

Steve


------------- Project Update -------------

June 29, 2008

Some progress today. It was a little slow since I took soooo much time just to get the timing belt on the engine. :censor: :censor: :censor:

Big thanks to Jodi Doyle for some help with the intake today (added some nipples for vacuum lines)

Anyway, new JE pistons are installed (still using Scat rods).
Image

And them purty?
Image

The turbo setup on yet another head. :censor:
Image

Those hard to get to nuts on the exhaust manifold.
Image

I bought a 10mm flex wrench years ago to be able to get those nuts in between the oil pan and transmission on my Rabbit. Well, it is the same tool that is needed for the Golf, but thankfully, only two bolts need this tool on the Golf.
Image

Close up of the end....
Image

In between oil pan and transmission....
Image

Close up of the bolt....
Image

5mm x 50mm bolt with head cut off + standard thread connector + 5mm x 50mm bolt cut to 10mm + (nut+washer+washer) + brad (nail) = "tool" to compress the timing belt tensioner.
Image

I had a hard time getting my hands into the tight spot so Julie gave it a go....
Image

Next project is to replace the bearing on Julie's Jetta (and do the brakes also... it still has my track compound pads on the front).

Then finish fixing the Cabbie....
Image

Then.... get the turbo Rabbit read for the next hillclimb.

Of course, around 11PM tonight I started to notice water coming under the garage door while it was raining.... so, I was outside in the rain cleaning the gutters over the front and back of the garage.

Steve
Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar
User avatar
Rabbit Farmer
SCCV Board Advisor
SCCV Board Advisor
Posts: 5193
Joined: Wed Jun 25, 2003 11:37 pm
Location: Milton, Vermont
Contact:

Re: Project: 2001 1.8T Golf IV

Post by Rabbit Farmer »

Okay, pictures should all be working.

The pictorial update..... :P :p

Wonder why MK4's have electrical issues? I have been finding a lot of problem wires in the harness as we unwrap and remove it. Image

Looky.... car is rolling on its own....
Image

And the turbo Rabbit. I plan on making it look a little more pretty, but in the nutshell, it is a fast and go-kart like handling car.

Image
Image
Image
Image
Image
Image
Image
Image
Image
Image

---------- Project Update --------

If you like Rabbits... here is the Rabbit I just sold (same builder as the turbo Rabbit above): http://forums.vwvortex.com/zerothread?id=3739880
I sold the linked Rabbit to purchase the turbo Rabbit (can't own them all).

And below, my wife's 89 Cabriolet 1.8t (original paint) that I need to change the clutch from mechanical to hydro and change the wiring harness from MegaSquirt to stock wiring with chipped ECU (friend will help with the wiring). I want it to drive like her 04 Jetta 1.8t (easy to drive). Right now the Cabriolet is 177 wheel HP and 190 wheel TQ. She goes like stink. :cool: You can see her 04 Jetta in there too. (100% stock except for Bilstein sport shocks/struts as the stock equipment completely failed within 3 years). I have had the Golf 1.8t and the Jetta 1.8t at the local tracks (i.e. Watkins Glen). Both are fun.

Image
Image
Image
Image
Image
Image
Image
Image
Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar
User avatar
Rabbit Farmer
SCCV Board Advisor
SCCV Board Advisor
Posts: 5193
Joined: Wed Jun 25, 2003 11:37 pm
Location: Milton, Vermont
Contact:

Re: Project: 2001 1.8T Golf IV

Post by Rabbit Farmer »

Image

I'm having my driveway sealed so we had to work on the car outside for the last two nights. It was hot, humid, a buggy as the sun went down. The car is all together and running okay on a tune that was downloaded from 034 (for the 1.8t, but for unknown turbo, etc.... just enough so it runs). I still have to properly mount some of the gauges (fuel pressure and boost) with the new mounts, but didn't have time before the dyno.

Dropped off the car at Quinitin's last night at 12:15AM for a dyno appointment on Wednesday....

Picking up Rabbit on Friday around 8AM to get that ready for the Okemo hillclimb in a couple of weekends. I am really hoping that Quintin's are able to get the Golf tuned or else I will have to do street tuning.
Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar
Post Reply