Mk4 Golf GT TDi 130 - A Quick Project
Discussion
mwstewart said:
I had an offer a few hundred off of the asking price, which was already higher than market average to reflect the work gone into it, but I rejected it. I think we're at a point where its more valuable to me than its net worth, so I'm going to run it for a couple of years 
I cant believe it didn't sell, even I would have bought that for its condition, and I cant stand Golfs, fantastic job you did on it.
qwertina said:
Thoroughly excellent work!
Thank you!Podie said:
I meant the BMW is for sale, the Ferrari and the Golf must be nearly done.... so just the Fiesta to do.
Oh, and when did this become your car? I thought it was the other half's car!
A couple of years ago.Oh, and when did this become your car? I thought it was the other half's car!
StuntmanMike said:
I cant believe it didn't sell, even I would have bought that for its condition, and I cant stand Golfs, fantastic job you did on it.
Cheers mwstewart said:
TT lower arms - shot blasted and coated, billet inserts so I can run the early TT front bush, LEMFÖRDER bushes and ball joints. Old bushes left in for coating purposes. As per the M3 project I found that LEMFÖRDER are the OEM supplier to VW and most of their parts have the OEM markings and numbers on them, and some come with the VW logo ground off. They cost a fraction of the VW supplied identical equivalent.
TT quick rack, LEMFÖRDER tie rods and ends, Cupra R ESP module coded ready for the quick rack, TT master cylinder and servo with two pressure sensors to suit the upgraded ESP program, and new OEM fluid and fluid port crush washers. I also went for Powerflex Black Series Polyurethane rack mount as I prefer solidly mounted steering racks.
The Cupra R and TT both run the same quick rack and upgraded ESP program, however for some reason the TT module - although still an MK60 - is wired very differently to the Cupra R, hence it makes more sense to get the latter. There are still wiring differences as I have found out, but nothing ridiculous. Here's my working out sheet in case it is of use to anyone else:
Hi Mark,TT quick rack, LEMFÖRDER tie rods and ends, Cupra R ESP module coded ready for the quick rack, TT master cylinder and servo with two pressure sensors to suit the upgraded ESP program, and new OEM fluid and fluid port crush washers. I also went for Powerflex Black Series Polyurethane rack mount as I prefer solidly mounted steering racks.
The Cupra R and TT both run the same quick rack and upgraded ESP program, however for some reason the TT module - although still an MK60 - is wired very differently to the Cupra R, hence it makes more sense to get the latter. There are still wiring differences as I have found out, but nothing ridiculous. Here's my working out sheet in case it is of use to anyone else:
I've followed your fiesta thread since I first it years ago, but have only recently caught up and found the other including the one for the golf. I did a very similar exercise a few years ago, however I stopped short of doing the rack at the time because people were reporting all sorts of issues on ESP equipped cars.
I'd like to give it a shot now due to a knocking rack and wonder if you can give me any more info. What are the differences between the TT and the golf servo/master cylinder unit? Was the ABS/ESP unit a straight swap barring the wiring changes (Thanks for sharing the sheet above!)? I bought one way back then suspecting it was the solution and its been sat on the shelf since. How did you code it and with what coding?
How have you found the durability of the Lemforder bushes? Have they lasted well?
Please keep up the posts, I have no idea how you find the time, especially with the cars stored away from home, but I'm glad you do somehow!
Edited by alistairolsen on Friday 2nd October 10:31
mwstewart said:
I had an offer a few hundred off of the asking price, which was already higher than market average to reflect the work gone into it, but I rejected it. I think we're at a point where its more valuable to me than its net worth, so I'm going to run it for a couple of years
This underlines a lot of these Golfs now. Excellent value, well put together and once you've upgraded the relevant parts, too good to just let them go for pennies.alistairolsen said:
Hi Mark,
I've followed your fiesta thread since I first it years ago, but have only recently caught up and found the other including the one for the golf. I did a very similar exercise a few years ago, however I stopped short of doing the rack at the time because people were reporting all sorts of issues on ESP equipped cars.
I'd like to give it a shot now due to a knocking rack and wonder if you can give me any more info. What are the differences between the TT and the golf servo/master cylinder unit? Was the ABS/ESP unit a straight swap barring the wiring changes (Thanks for sharing the sheet above!)? I bought one way back then suspecting it was the solution and its been sat on the shelf since. How did you code it and with what coding?
How have you found the durability of the Lemforder bushes? Have they lasted well?
Please keep up the posts, I have no idea how you find the time, especially with the cars stored away from home, but I'm glad you do somehow!
Hi Alistair,I've followed your fiesta thread since I first it years ago, but have only recently caught up and found the other including the one for the golf. I did a very similar exercise a few years ago, however I stopped short of doing the rack at the time because people were reporting all sorts of issues on ESP equipped cars.
I'd like to give it a shot now due to a knocking rack and wonder if you can give me any more info. What are the differences between the TT and the golf servo/master cylinder unit? Was the ABS/ESP unit a straight swap barring the wiring changes (Thanks for sharing the sheet above!)? I bought one way back then suspecting it was the solution and its been sat on the shelf since. How did you code it and with what coding?
How have you found the durability of the Lemforder bushes? Have they lasted well?
Please keep up the posts, I have no idea how you find the time, especially with the cars stored away from home, but I'm glad you do somehow!
Edited by alistairolsen on Friday 2nd October 10:31
In the end I did not install the TT ESP unit and wiring - I first tried with the original parts.
The car has new tyres, straight wheels, and a underwent a couple of full alignments (actually TT spec not Golf GT) to get to a point I was happy with, and after driving for 5k miles I have no intrusive ESP issues whatsoever with the V6 rack.
There are some possibilities:
1) Others who have issues with the rack swap need an alignment (the OEM ESP coding has a tolerance for variations and it is breached by changing the rack and driving with misalignment);
2) Others have not been mindful of the steering angle sensor and its reference position needs to be reset;
3) The difference in ratio between my original GT rack and the V6 rack was not as great as others. My 2001 GTi for example had a vastly slower rack than this PD130 GT TDi.
Cheers,
Mark
mwstewart said:
Hi Alistair,
In the end I did not install the TT ESP unit and wiring - I first tried with the original parts.
The car has new tyres, straight wheels, and a underwent a couple of full alignments (actually TT spec not Golf GT) to get to a point I was happy with, and after driving for 5k miles I have no intrusive ESP issues whatsoever with the V6 rack.
There are some possibilities:
1) Others who have issues with the rack swap need an alignment (the OEM ESP coding has a tolerance for variations and it is breached by changing the rack and driving with misalignment);
2) Others have not been mindful of the steering angle sensor and its reference position needs to be reset;
3) The difference in ratio between my original GT rack and the V6 rack was not as great as others. My 2001 GTi for example had a vastly slower rack than this PD130 GT TDi.
Cheers,
Mark
Thanks mark,In the end I did not install the TT ESP unit and wiring - I first tried with the original parts.
The car has new tyres, straight wheels, and a underwent a couple of full alignments (actually TT spec not Golf GT) to get to a point I was happy with, and after driving for 5k miles I have no intrusive ESP issues whatsoever with the V6 rack.
There are some possibilities:
1) Others who have issues with the rack swap need an alignment (the OEM ESP coding has a tolerance for variations and it is breached by changing the rack and driving with misalignment);
2) Others have not been mindful of the steering angle sensor and its reference position needs to be reset;
3) The difference in ratio between my original GT rack and the V6 rack was not as great as others. My 2001 GTi for example had a vastly slower rack than this PD130 GT TDi.
Cheers,
Mark
Worth just giving it a shot then since the rack needs to be replaced anyway. The TT components make a very pleasing difference to the golf platform!
I may get lucky on the rack ratio, mines a PD130 too, and although slow, the rack isnt horrendous. I ought to count the turns I suppose!
Yeah I went with lemforder for all the joints last time, however with the bushes it was difficult to isolate specific ones like ibiza or fabia cupra/vrs rear beam bushes so I went to the dealer for them. I've pinched your part numbers for my parts guy this time around!
Cheers
The Golf is still going strong. It went to VW recently for a service at 72k miles, and given it's over 13 years old it did very well indeed:
I've fitted a new Bosch battery as the engine was beginning to turn over a little more slowly on cold mornings. It's now back to how it should be.
I've fitted a new Bosch battery as the engine was beginning to turn over a little more slowly on cold mornings. It's now back to how it should be.
mwstewart said:
The Golf is still going strong. It went to VW recently for a service at 72k miles, and given it's over 13 years old it did very well indeed:
I've fitted a new Bosch battery as the engine was beginning to turn over a little more slowly on cold mornings. It's now back to how it should be.
I thought you sold it ?I've fitted a new Bosch battery as the engine was beginning to turn over a little more slowly on cold mornings. It's now back to how it should be.
I wouldn't be surprised if there's 100k left in it A quick maintenance task today. My car suffered the usual Mk4 Golf fate of a cracked centre console and was saddled with the associated rattles & squeaks that come with it. I purchased a new OEM console from a VW dealer selling parts on eBay:
To ensure this doesn't happen again I smeared Sikaflex along the join between the upper and lower console, whcih is where the OEM plastic welding usually breaks.
I also took the opportunity to remove the glove box and apply a combination of felt tape, adhesive backed felt, and anti-vibration compounds on all contact surfaces.
I use round felt pads and hole punch pliers to create little felt washers to use around screws and bolts.
I now have a quiet car once again, and for a Mk4 Golf diesel - it's pretty good.
To ensure this doesn't happen again I smeared Sikaflex along the join between the upper and lower console, whcih is where the OEM plastic welding usually breaks.
I also took the opportunity to remove the glove box and apply a combination of felt tape, adhesive backed felt, and anti-vibration compounds on all contact surfaces.
I use round felt pads and hole punch pliers to create little felt washers to use around screws and bolts.
I now have a quiet car once again, and for a Mk4 Golf diesel - it's pretty good.
I'd forgotten about this thread and the effort you'd put into it. Sold my 1.8T in the end, never really agreed with it and it wasn't as reliable as hoped. The only thing I miss about it is the heated Recaro seats. Mega comfortable, even after a few hours in the saddle. Replaced it with an E46 325ti. Much prefer that as a daily, and so far has been rock solid.
At the start of the year I thought to myself the car must be getting to an age - 14 years - and mileage - 75k - where the life of the alternator is coming to an end. Sure enough last Tuesday the 'Alternator - visit workshop' message appeared briefly on the FIS.
On the Mk4 Golf 1.9 the two most likely causes are:
1) Failed aux belt tensioner
2) Seized clutch pulley on the alternator
The car managed a bit more city driving and a two hour motorway trip before the warning came on again, this time followed by a grumbling from the engine. In my case the pulley had seized but given the age of the car, and the fact the tensioner itself can also cause a similar problem, I decided to replace the tensioner and the entire alternator, rather than simply replace the clutch pulley. I decided to go for a Lucas 120amp alt rather than the 90amp version currently fitted.
The alt is in a really accessible place and is the easiest removal job I've ever done - it can be done in 15 minutes without rushing. Amazing!
Offending part(s).
Euro Car Parts have an Easter deal on and the replacement parts cost just £111 after returning my old alternator.
On the Mk4 Golf 1.9 the two most likely causes are:
1) Failed aux belt tensioner
2) Seized clutch pulley on the alternator
The car managed a bit more city driving and a two hour motorway trip before the warning came on again, this time followed by a grumbling from the engine. In my case the pulley had seized but given the age of the car, and the fact the tensioner itself can also cause a similar problem, I decided to replace the tensioner and the entire alternator, rather than simply replace the clutch pulley. I decided to go for a Lucas 120amp alt rather than the 90amp version currently fitted.
The alt is in a really accessible place and is the easiest removal job I've ever done - it can be done in 15 minutes without rushing. Amazing!
Offending part(s).
Euro Car Parts have an Easter deal on and the replacement parts cost just £111 after returning my old alternator.
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