Mk4 Golf GT TDi 130 - A Quick Project

Mk4 Golf GT TDi 130 - A Quick Project

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mwstewart

Original Poster:

7,608 posts

188 months

Friday 24th January 2014
quotequote all
A friend of mine asked for some car related advice and for help with finding a nice car for his girlfriend. The budget was £6k. I provided several options including the Golf I'm writing about in this post, which was to be fair the wild card int the bunch being both older and cheaper than the other options. It was a suggestion made to actually save her some money long-term, however she dismissed it as being too old. I did not, and the more I thought about it the more I decided it would be perfect for my girlfriend, so I bought it instead!

It's a 2002 GT TDi 130, 1 previous owner, 38k miles, and FVWSH

For a Mk4 Golf, it was quite well-specced with: 6 CD changer, Auto dim mirror, Auto wipers, Climate Control, Full-height FIS/DIS, Multi function steering wheel, Rear parking sensors in a better looking rear lower valance. The other thing that made it perfect for my girlfriend, aside from being a Mk4 Golf (she loves them), was the paint; "storm grey" is her favourite colour. VW call it Blue Anthracite Peal.

Generic photo:



This is a post about some of the changes I made to the car to make it a bit more special for her. It was a quick project and this was typed in a rush, so please excuse and spelling and grammar mistakes in advance.

I drove the car home from the dealer, changed the 15" 'Avus II' alloys for a set of 'Montreal II', and swapped my girlfriends existing Golf key with the new one. It was a nice surprise when I asked her to look what I'd done to her car!


UK, France, Switzerland
I thought we better put some miles on the car to make sure it was OK. I had managed to get a slot on the Dover to Calais Ferry the next morning, at 5am, so we set off for a bit of a road trip.

The route ended up London > France: Rouen, Évreux, Orleans, Châteauroux, Clermont-Ferrand, Montpellier, Marseille, Italy: Turin, Switzerland: Genva, Dijon Reims, then home.

It was a bit of a whistle-stop tour but great fun. There is a degree of head-bending required for a few of photos, sorry in advance!







Planned to camp for a few nights, but one night was enough!























































Aside from the front wheels being slightly out of balance, the car was absolutely fine.

The beginning
So, on to the reason for this post. I decided to spruce up the Golf a bit and create something a bit nicer for my girlfriend. Nothing with sporting pretensions, just a better specification with features that would make daily driving more enjoyable. Here is what I started with:



Custom Heated Leather Recaro Interior
I wanted to add heated, leather Recaros to the car and I really like contrasting interior colours, however if beige leather ordered then the entire bottom half of the interior is also beige, and for me, that is a bit much.

Generic photo:


I bought a used Recaro interior, which was hard to find in beige for a 3 door, and even harder to find in reasonable condition. I used Autoglym trade cleaner to remove any grime, and some liquid leather on the drivers bolster to make it look new again. First step was the head seat loom, which was actually quite straight-forward to integrate, as the previous owner had done a fine job of removing it carefully. A rare thing!


I laid the loom in OEM locations, the only exception was I added an additional under-seat loom protector rather than trying to pick my original one apart.


I bought a second hand fuse box to remove the necessary terminals from. I don't have access to VW parts systems (ETKA I think? I had it years ago) so quicker.


My plan was to install the cream recaros and rear benc, and cut the beige leather inserts from the Recaro door cards, and bond them in place of the cloth black inserts currently in the car. I used an angle grinder to remove the plastic welding tabs.


I was left with this - incidentally these are vinyl along with the seat backs, and sides.


I bonded the 'leather' inserts to my black door cards.


I also added vibration damping material in preparation for an improved sound system.


Headlining and Pillars Re-trimmed in Nu-Suede
Next up the headlining. I don't like the standard light grey colour so decided to re trim everything in black 'Nu Suede' from Dunelm Mill.


I sprayed all of the grey trim pieces in black vinyl paint.


I managed to get an acceptable -not perfect - result.






25th Anniversary Black Headlining and Pillars
The not-qui-teperfect headlining bugged me, so I tracked down a genuine '25th Anniversary' headlining, roof furniture and black door seals. I ordered a complete set of new trimn fixings from VW to ensure there were no undue noises given the trim had been off once already.


I also added slient coat products where appropriate, which did stop a bit of noise from behind the C pillars.


I also used Anniversary trim this time, so things like the interior lights were black and had white icons - something which was lost when I painted my originals..


Perfect.


Custom Instrument Cluster
The Mk4 Golf cluster (right) looks a little 'clunky'. The Passat (left) version of the same era is much nicer, and more precise looking


The cluster architecture is fundamentally the same for each although there are electronic differences which make fitting the Passat cluster less than straight forward. My appraoch was to modify my existing cluster rather than swap anything.


I stripped down each cluster, then chopped up the Passat Foils and glued on the speedo and rev counter part to my Golf temp and fuel sensor foils. I did this because the sweep on the passat fuel & temp gauges is different and would require an EEPROM update to fix - not worth it for me. I also bored out the Golf dial bezel to accept the Passat cluster rings.


Completed Golf cluster with Passat needles etc. Setting the needle start point proved to be a little tedious!


Aero Wipers
Aero Wipers were fitted from MY2004, and are a direct fit.


DSP Sound System
I chose to retrofit the factory uprated sound system, and I'm, really glad I did! Teh speakers are uprated and it is all driven froma seperate amp in the boot.

The speakers. Standard paper cones, left, and DSP, right.



I used a retrofit loom from Kufatec, which was beautifully made and labeled. Doing it this way keeps everything as OEM as possible, which helps with any future diagnosis when required.


Standard speaker in rear quarter area.


DSP speakers fitted, and any apertures blocked up with Silent Coat. I did this to improve bass response.



I combined another couple of infotainment retrofit looms with the DSP loom, which I'll detail later in this post.


Kufatec loom run in factory location.


Front speakers installed and more silent coat added.


In the boot area I install two additional rivnuts in factory locations, to allow the DSP amp bracket to bolt up.


The boot carpet trim is also different for DSP equipped cars, but I found it was simple enough to modify mine.


Here's the amp fitted. I coded it using VAG-COM, which adjuts some of the EQ to suit the Golf interior (also the leather seats).


MFD1 Sat Nav Revision 'G', TMC Module, Media Module, Reversing Camera
I chose to fit revision 'G' of the MFD Sat Nav as it was the latest released and has predictive input. The unit was fitted to Passat's only after a date which followed the Mk4 Golf production ending, hence there are some electrical differences.

Because my car is fitted with a full height driver information system, which is supplied by CAN, I must also fit a specific version of the - optional when new - TMC tuner box which in addition to TMC routing, functions as a CAN gateway between the proprietary Blaupunkpt media CAN bus and the CAN-LO 'standard' CAN that my instrument cluster uses for its display. I forget the exact TMC version number now, it's either 3B0919894 or 3B0919894 A. Some other enthusiasts figured this out a long time before I started this project, so I am using the benefit of their experience.

Here's the nav and retrofit parts. The TMC unit is the silver box.


The dash came apart to route cables neatly, but also because I was working on a lot of other things at the same time.


I mounted the TMC unit above the convenience module, under the n/s of the dashboard.


I also installed a media inteface, so an iPod and reverse camera could be used with the MFD.


Media interface wiring and behind the glove box, ready for connection inside the glove box itself. I have wired the unit to show the reverse camera automatically when in reverse.


Night vision reverse camera installed.


I also bought some new VW knobs for the MFD, to freshen it up.


Bora Illuminated Vents
Bora vents are of a more modern design, and the icons are illuminated. I fitted a set of these using a retrofit loom from eBay. Very much over-priced but it saved me a bit of time.


Glove Box CD Changer
The 6 CD changer was mounted in the dashboard double DIN slot, along with the original single DIN CD. Golf CD changers are usually the magazine type mounted in the boot, but I find they are a pain to use. I chose to cut/modify the glove box to mount the dash-based version in there.


Mounted and much more useful within reach of the driving seat. The module mounted underneath is the media interface for the MFD.


Sealed up
I found condensation in the tyre well and upon investigation found that the rear cabin air vent seals had dropped, and were letting in water.


Rear bumper off, vents removed and refitted using RTV instead of the VW foam seals.


Completed
I added a walnut wood trim kit, and matching walnut gearknob. The gear gaitor is also from a Bora with its chrome ring. The gaiter was from eBay.


The finished article. My girlfriend is really happy with it.


mwstewart

Original Poster:

7,608 posts

188 months

Saturday 25th January 2014
quotequote all
Thanks all. A remap isn't on the cards, I'm not sure it would be noticed biggrin It's a sweet little package in standard form.

mwstewart

Original Poster:

7,608 posts

188 months

Saturday 25th January 2014
quotequote all
aspirated said:
I'm surprised you haven't fitted a set of OEM projector headlights with HID xenons wink
Ha, I have those, the 5.5L washer bottle, jets, piping, and wiring adapters.

I just need the Kufatec self levelling loom now and some time to fit everything.

mwstewart

Original Poster:

7,608 posts

188 months

Saturday 25th January 2014
quotequote all
Thanks everyone. I've used the car a few times and it's actually very pleasant to drive. My g/f had a 2001 GTi prior to this and the steering can be likened to turning a wooden spatula in heavy porridge, this new one however is a world away, in fact it's not far off the M3. VW must have taken heed of the criticism and made steps to improve the platform though public opinion of course was already made up.

The route consisted of Rouen, Évreux, Orleans, Châteauroux, Clermont-Ferrand, Montpellier, Marseille, Italy: Turin, Switzerland: Genva, Dijon Reims, then home.

I have some Bora Sport clocks for the car, but decided they were a bit flashy.


Speak of the Xenons reminded me that I really need to fit them, so I dug them out today. I will write up the steps required to fit them.


I also found this, which just needs a 20mm hole boring in the O/S boot carpet. All Mk4's that I've seen are pre-wired for it.

mwstewart

Original Poster:

7,608 posts

188 months

Saturday 25th January 2014
quotequote all
jimbop1 said:
Seats
Apologies: I paid £280 for essentially a complete interior plus the heated seat loom and switches. I got all plastics with that too, though I didn't use any of them. I kept seeing the same interiors on eBay at £380, even £500 which is too expensive given the average age & value of the Mk4.

You would be very surprised at what the interior looked like when I collected it; it was the best interior I could find but still looked quite grim before I cleaned it with trade strength cleaner.

mwstewart

Original Poster:

7,608 posts

188 months

Sunday 26th January 2014
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jimbop1 said:
I do apologise for just writing seats... It looked very rude!

I expected the seats to be more than that. You must have done a very good job cleaning them up. Where they easy to fit?
Ha, I did think it was quite rude smile

Refined Detail said:
Safe to say I'd be very happy to buy an car previously owned by you I think! laugh
It's a shame you're not closer, I would like my M3 detailed ready for sale.


strummerville said:
My wife had one if these a a company car in 2002. It was a black 3 door. They let her have the PD130 as their Golfs were all 5 door 115PS versions, but let her have the 3 door as it was closer in price.

At the time it was one of the first performance diesels and (if IIRC) had 236 lb/ft torque which used to make the rear squat and go with a puff of black smoke. I also remember it was a six speed manual, not 5.

Nice car, except for the seats which were typically hard, uncomfortable Germanic fare!

I once got the fuel computer to a 70mpg average coming back from the V Festival late at night on the M6. A rare thing in fact - a company motor that had some charisma and one that I can remember fondly.
I think 57 is the best so far smile I can imagine the Mk4 was well above average in its heyday.

mwstewart

Original Poster:

7,608 posts

188 months

Monday 27th January 2014
quotequote all
Thanks all. Aside from the Xenon's, it is finished smile

mwstewart

Original Poster:

7,608 posts

188 months

mwstewart

Original Poster:

7,608 posts

188 months

Saturday 31st May 2014
quotequote all
The OEM Xenons are finally in. The headlamps have a projector low beam rather than reflector; they aren't Bi-Xenon but still better than the original H7 Halogen low beam on the car. Thankfully the high beams in the Mk4 Golf are actually pretty good anyway.

I don't have many photos from the process as I only had an afternoon to fit them - which sounds enough - but the mounting position of the ballasts precipitated removal of both front wings in addition to the front bumper! I could have fitted the 2003+ type which had integrated ballasts but I wanted to keep the correct type for the year of car (2002).


The levelling system and headlamp washer systems are in, but I'm not quite legal yet as I require the washer system retrofit loom from Kufatec. It's on my list before the car goes to VW next month for a major service.

mwstewart

Original Poster:

7,608 posts

188 months

Saturday 31st May 2014
quotequote all
martin mrt said:
Cracking project Mark, missed this initially, it's almost exactly the same as my old 150 GT TDi, except mine had black leather recaros as standard, the rest of the spec your retrofitting mine already had, should have kept that car.
Cheers Martin. That sounds like a very rare car indeed!

mwstewart

Original Poster:

7,608 posts

188 months

Monday 1st September 2014
quotequote all
I may have mentioned previously that I'm using the Golf very regularly now that my g/f has a company car, and with frequent use it has now reached 60k miles. It's covered the past 22k in our ownership needing only a set of tyres and a battery, which happenend to be the original. We've been extremely pleased with it.

I've used VW for servicing and found that their basic service, by basic I mean oil & filter, is incredibly good value at £99. I change the additional items myself at the same time i.e. fuel, oil and pollen filters. The cam belt is due now so I shall get it changed also.

I'll probably keep the car until next summer, then get it serviced & MOTd before advertising it.


mwstewart

Original Poster:

7,608 posts

188 months

Monday 1st September 2014
quotequote all
Max M4X WW said:
I agree about the servicing, our A3 was done by Audi last year - It was a bit more at £149 but that included them painting the roof and repairing some rust under warranty. It was the only way they would do it FOC.

Do let me know how much you'd want for it, I'd quite like to own an ex MWS car and our A3 is a bit on the tired side!
With pleasure, Max. I'll give you a shout next year, though the only thing is I'm not sure if the exterior will be up to your high standards; it's lived most of its life in London and hence has picked up some scratches and small parking dents here and there. Nothing horrific, but nothing close to the cars you've had. Mechanically it's perfect.

alangtt said:
Hi great upgrades,
You say the rear already has the wiring fit the 12v socket? Anymore info
It would be ideal for camping
Thanks Alan. I beleive all Mk4's have the wiring taped up behind the O/S/R light cluster. If you pull back the O/S/R boot carpet you will see a cream coloured two pin connector. The required parts are:

1J0919309 - £3.95
7L6919341F - £4.31

Just bore a 20mm hole in the boot carpet and mount the socket within reach of the connector.

mwstewart

Original Poster:

7,608 posts

188 months

Monday 1st September 2014
quotequote all
BBS-LM said:
Did you really pay 6K for a Mk4 Golf GT TDi 130 which was 12 years old?
No: "The budget was £6k. I provided several options including the Golf I'm writing about in this post, which was to be fair the wild card in the bunch being both older and cheaper than the other options"

mwstewart

Original Poster:

7,608 posts

188 months

Saturday 6th September 2014
quotequote all
The Golf's rear discs and pads were ready for replacement along with its brake fluid. I priced up a premium brand set on ECP which came in around £85 including fluid - which wasn't bad at all - however I decided to go a different route. I've never been entirely happy with the brake bias on the car; it's way too front biased! Given I would be changing the fluid anyway, I decided to search eBay for an upgrade. I found the following set:


It looked like it had been washed up on the last tide, but I could see a decent set of brakes underneath with new discs and pads. I paid £77 delivered! The brakes are vented 25mm in diameter from the rear of a FWD TT. The original set up on the Gold was 230mm sold discs.

Here they are fitted. They have made a subtle but noticeable difference to braking balance and have inceased braking power overall.


VW gave the car a good clean after its service, and I was thoroughly impressed with the service at Vertu VW in Lincoln - a very pleasant experience all round.



mwstewart

Original Poster:

7,608 posts

188 months

Saturday 6th September 2014
quotequote all
Gingerbread Man said:
Front your first post, where is the pipeline situated?
I'm afraid I don't remember the exact location, but it's somewhere within the Réserve Naturelle de la Vallée de Chaudefour.

mwstewart

Original Poster:

7,608 posts

188 months

Sunday 7th September 2014
quotequote all
alangtt said:
Brakes a direct fit?
Yes, they are aside from trimming of the disc splash shield to suit the larger discs. The Quattro versions do fit but require a 6mm wheel spacer hence I used the FWD TT versions.

The new discs are in fact 256mm not 25mm as I mistakenly typed in my previous post.

BE57 TOY said:
Exceptional work!!
Cheers smile

mwstewart

Original Poster:

7,608 posts

188 months

Thursday 11th September 2014
quotequote all
New headlamp washer jets and covers from VW, and the Kufatec loom. I used http://uk-mkivs.net/topic/10738-wiring-for-headlig... to install the loom and it went without a hitch. The Kufatec products really are great.


The systm is now up and working - just in time for an MOT on Monday.

mwstewart

Original Poster:

7,608 posts

188 months

Sunday 2nd November 2014
quotequote all
I just had the cam belt, water pump, and aux belt changed. I think it was the original belt so it was well overdue based on age, but not mileage.

During my routine checks I noticed that the OEM quick release fittings on the boost pipework had succumbed to the leaks at their joints which with these is an inevitability, so following my 'replace parts with upgraded versions' ethos I ordered this:


The standard car never feels slow but I am really looking forward to some more power.

mwstewart

Original Poster:

7,608 posts

188 months

Sunday 2nd November 2014
quotequote all
Max M4X WW said:
Looks good Mark, I actually replaced all the seals on ours and it seems to have done the trick for now. The standard inter cooler does seem to get quite hot though!
On mine the triangular locating tabs on the hoses had worn away the corresponding recess in the intercooler, so in my case seals would have only bought me a bit of time. The Darkside kit is such good value for money I had to get it - hopefully trouble free for quite a few miles smile

epom said:
You need to find a hobby smile!superb work Op smile
I do biggrin Cheers.

mwstewart

Original Poster:

7,608 posts

188 months

Sunday 2nd November 2014
quotequote all
Max M4X WW said:
Mine were a bit worn, but surprisingly it all seems tight now even with over double the mileage of yours.

I think the Darkside kit uses the £100 ebay intercoolers, but I guess the money is in the pipework really. For me, £350 on a car that is worth 2k (I hope!) and has caused me a few problems wasn't worth it.
That does come into it for sure - I'm not sure mine is worth a whole lot these days, but it is to me. I've grown quite attached to it biggrin