Mk4 Golf GT TDi 130 - A Quick Project

[mwstewart]

I've had a bit of a game with alignment over the past week; on Tuesday I took the car to F1 Autocentres in Lincoln to have it aligned to TT 'Sport' (fast road) spec and we just could not get the O/S/F camber anywhere near -1.30°: it was stuck around -2.30° on the minimum setting. The N/S/F was set up perfectly and somewhere in the middle of its adjustment range so clearly something wasn't right. I took the car away for further investigation.

I spent a few hours in the unit yesterday trying to get to the bottom of it and after the first round of measurements I found the O/S/F wheel Set Back was around 15mm, and that is way more than could or should be corrected by slackening the subframe or lower arm mountings and repositioning them. The TT subframe mounted to the car without any issue and had no signs of damage but I decided to measure all of its mounting positions and cross reference them with some taken from my old Golf subframe, which was known to be good.

In the end I found that the lower arm rear mounts were closer together by 5mm which of cause is sufficient to create a more significant problem at the wheel face, so it seems that the TT had taken a knock to the O/S/F wheel significant enough to compress the rear section of subframe slightly thus canting the wheel backwards in the arch and moving the minimum camber point outwards in the process.
To resolve the issue I ended up swapping the TT 3.2/Roadster subframe with my original Golf version which thankfully is in pretty decent condition. The car went back to F1 Autocentres today and they corrected everything free of charge – nice service!

It's worth pointing out that F1 Autocentre use a Supertracker machine which won't calculate Set Back like a Hunter will - otherwise the issue could be more clearly diagnosed during alignment - but for the purposes of aligning in normal circumstances the Supertracker is absolutely fine, and I really like the level of customer provided by F1. During alignment I'll be stood under the ramps with the technicians discussing cars! They also aligned the F430 for me after I fitted the Hill tie rod ends, and were very careful with the car.

Here are the results:

Front toe: perfect.
Front camber: ignore the fact it's shown in red: that's because I've ignored the Audi standard settings and gone for a fast road camber spec.

Rear toe: I have a small (3mm) toe out setting to correct on the N/S/R wheel likely caused by me unbolting the rear beam mount on that side when I replaced the bushes, but it's quite insignificant so can wait until another time.
Rear camber: OK.

I will report in a later update how the car handles.

In other news I have bought a new OEM Triplex Antenna (GPS, Radio, and phone) to replace my standard aerial. It is the finishing touch for the Sat Nav/MFD retrofit.

[mwstewart]

Thanks both

Very small update. I played around with the rear beam and went back for another alignment - got it much closer this time.

I also bought a copy of VCDS and did some data logging one Sunday afternoon just to check over the car, as I felt the performance wasn't quite what it used to be. I noted that the temp sender reading was falling a few degrees outside of the 87 to 92 degrees C range, so I replaced that and the car feels back to full health again. I checked over the MAF readings too and all was well. I also coded out EGR from the ECU and the difference is considerable - where the car would previously labour in 4th gear at 30mph (I don't drive like that!) it is now smooth. Really pleased with that.

I had four new Conti Sport Contact tyres fitted too - great daily use yres for a non-sports car.

The car will be for sale in March at somewhere over but close to £4k. 67k miles.

[mwstewart]

JakeT said:

Mark-

How has it been running a mk4 golf over the past year or two you've had it? For about a week I've been running a mk4 GTi as a courtesy car. While it had the heated recaros and a surprisingly good aftermarket Alpine stereo it ends up leaving me cold. It's well built, quick enough that it doesn't embarass itself but I never want to just go out and drive in it. It feels a little clinical to me. Also the clutch pedal has a bloody long throw! I'm wondering if your treatment made the car feel better or if it kept the same feel to it?

Also what's going to replace it? I recall talk of an AMG Merc this year?

Hi Jake,
I must admit I've loved the thing, but I did have two early ones prior to this one and didn't think quite so much to them. The 1998 to 2002 models differ in spec to the 2002 onwards by their front subframe bushes, spring rates, steering rack, and anti roll bar setup. The early GTi I had just felt a bit lifeless in comparison: vague steering, wallowly ride, and zero feedback, but then haing said that I don't think any model based on this platform regardless of manufacture date will ever replace a purpose built sports car or a decent hot hatch - they are just great at the everyday.

The TT changes I've made have transformed the car again. The quick rack is great! I rarely need more than half a turn. There is a quality of damping in the Golf that I think seperates them from other cars too, only now I have less body roll and a much higher level of feedback thanks to the TT parts and geo. The quick rack helps no end when pushing on as it'll flick its tail round and push into a four wheel slide with ease! On a couple of drives now it has actually put a smile on my face

The clutch pedal in mine hasn't stood out...

I am looking at the CLK63 Cabriolet but now wondering if it will be focussed enough for the little time I spend in a car these days, hence I'm giving serious consideration to running my M3. It's never going to be worth a fortune so the only person benefitting from it being stuck in my unit unsed for months at a time is the eventual next owner.

Cheers.

Remagel2507 said:

Considering the amount of work gone into it and the attention to detail I'd say that's a very reasonable price

Thanks!

[mwstewart]

aspirated said:

Mark, considering your experiences with various ages of MKIV Golf, would you recommend the earlier style 'fixed ring' cupholder or later adjustable arm type? My MKIV currently has no cupholder and I'm leaning towards fitting the earlier type as the arms on the later one could be prone to failing? They don't inspire much confidence either, and I'm not going to be carrying any silly sized drinks

The later version is better. The early one is fiddly to use.

[mwstewart]

Mikeyplum said:

Excellent build yet again Mark. I've had a Bora 130 for over 5 years and have recently bought a 2004 Golf TDI PD130 so will be taking a lot of lessons from this thread.

Would you mind posting any links, or pointing me in the right direction for the interior ally trim please?

The alloy trim is much harder to get hold of, as you may have realised. Try eBay or ukmkivs.

[mwstewart]

Barchettaman said:

What an unbelievable (re)build.

Best of luck with sale, assuming it´s happening this month.

Thank you

[mwstewart]

Usget said:

Cheers in advance.

PSB.

Usget said:

1) What were the B4s like? Would you recommend them? I don't particularly want to lower the car (I guess being a Sport it is on the firmer springs in any case, same as a GTI 1.8T?) but I'm keen on some greater damping control.

Yes, I would. Very nice road dampers.

Usget2 said:

Did the 312mm discs make a big difference? Only the carriers need swapping on the 1.8T Sport, the calipers are the same, so I'm considering combining the bigger discs with some braided hoses for a more meaty set of stoppers - what was your experience?

They made a fantastic difference - the difference between having to stand on the anchors and having some modulation in reserve. Very worthwhile.

Usget said:

3) How fiddly was modifying the splashguard to accomodate the rear 256mm discs?

Not really - I just cut off the periphery.

Edited by mwstewart on Monday 27th April 14:35

[mwstewart]

Usget said:

Thanks for the swift reply. I don't see where the Pet Shop Boys come into it, though...?

You know what I mean, you little tinker.

[mwstewart]

There were a few months MOT remaining but I had a new one undertaken yesterday.

Now for sale http://www.ebay.co.uk/itm/WV-Golf-Mk4-1-9-TDi-130-...

[mwstewart]

The Golf is still going

The only problem I've had is the front exhaust/cat section rotting out at a join. I've replaced it with a stainless section:


Mileage is now 70k, and she's due a basic service at VW.

[mwstewart]

JakeT said:

Good to hear it. Just got myself a Mk4 GTi Turbo and like it for what it is. It's not a raw hot hatch but makes for a good cruiser. There's a couple of things I need to do to the thing (got some Montreal II alloys on the way) but what would you recommend for these cars? It's already got cloth recaro seats and the winter pack. Also it has an excellent aftermarket amp and speakers in it.

In order:

1) The TT front hub and arm conversion with defcon inserts & early bushes;
2) TT 2WD struts and springs, and early front ARB;
3) V6 TT quick rack.

The above makes a big difference to how the car drives. You can use second hand parts to keep costs down, though it is well worth changing lower arm bushes (£4.75 small, £7.56 large) and ball joints (£26.52).

[mwstewart]

martin mrt said:

Nice to see your still running the Golf Mark.

Have you decided not to bother selling after all?

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

[mwstewart]

Podie said:

Won't you get bored when you have nothing to tinker with?

I'm not selling the Golf just yet, and the other car is a project too

[mwstewart]

JakeT said:

Good advice. Thanks. The front and rear end have been re bushed, so the thing handles as it was meant to but it still is a little soft. How much quicker is the V6 TT steering rack? The Golf feels like a bus in comparison to Fiestas and other things I've been driving recently. Also, is the V6 TT rack a straight swap? Mine doesn't have ESP or ASR so less of a headache there.

The TT bushes are specific to that model with the rears being solid - unlike the Golf's void bush - and the fronts are very small to aid steering feel and prevent geo changes.

Also change the rear beam bushes for Fabia VRS or Cupra-R. Again, they are not void bushes but are still comfortable enough for daily use.

The rack is a straight swap and makes a big difference. I had an early Golf and it felt like how I imagine piloting an ocean going cargo ship would, mine now in comoparison is good fun.

[mwstewart]

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.

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]

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!

Edited by alistairolsen on Friday 2nd October 10:31

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

[mwstewart]

P.S. Lemforder are OEM parts. Some arrive with VW/Audi logos still on, and others with the OEM logos ground off.

[mwstewart]

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.

[mwstewart]

No, I still have it.

[mwstewart]

leglessAlex said:

But Mark, there are three ticks in the yellow section! Poor form

Good to see it's still going strong.

Most unaccetable I wouldn't be surprised if there's 100k left in it