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Eurocars build thread

eurocars

5/17/15 - Never forget
Location
Indianapolis
Ride
2006 GTI
Went live today with the battery, no smoke and no fires. Was a little nervous after lots of wiring work over 2 years. No engine fault codes either.

Only issues i noted so far is that somehow all of the central conv. coding reverted back to factory, the brake switch turns off the lights instead of turning them on (not sure if coding or wiring since i went with a MK4 switch), the coolant level sensor is beeping even though i wired it so it should be off, and even though my headliner was in perfect condition when i parked the car i noticed today that the entire center section has separated. Only noticed it when the wife went to put the battery cables on and hit it with her head.

Next week I’ll swap in the built trans, wrap the rest of the engine harness and start installing the rest of the drivetrain.

To do:

Fill all fluids
Double check all engine hardware torque
Loom rear section of engine harness
Swap transmissions
Bolt up axles
Route PCV hoses/figure out catch can solution
Put new fuel in tank

After that it’s driving. Not sure if the 70A alternator is enough, but we’ll find out
 

bon qui qui

Go Kart Champion
Location
Charlotte
Went live today with the battery, no smoke and no fires. Was a little nervous after lots of wiring work over 2 years. No engine fault codes either.

Only issues i noted so far is that somehow all of the central conv. coding reverted back to factory, the brake switch turns off the lights instead of turning them on (not sure if coding or wiring since i went with a MK4 switch), the coolant level sensor is beeping even though i wired it so it should be off, and even though my headliner was in perfect condition when i parked the car i noticed today that the entire center section has separated. Only noticed it when the wife went to put the battery cables on and hit it with her head.

Next week I’ll swap in the built trans, wrap the rest of the engine harness and start installing the rest of the drivetrain.

To do:

Fill all fluids
Double check all engine hardware torque
Loom rear section of engine harness
Swap transmissions
Bolt up axles
Route PCV hoses/figure out catch can solution
Put new fuel in tank

After that it’s driving. Not sure if the 70A alternator is enough, but we’ll find out
That headliner issue is exactly what happened with my car :cry:
 

clownish

just clowning around
Location
Ohio
My Golf, Passat and now GTI all have saggy headliners


That headliner issue is exactly what happened with my car :cry:


My mk5 also had this happen.

I scheduled an appointment with an interior team who is scheduled out till mid September. It will also cost a few hundred... which I think I’m okay with because the interior is immaculate except for the tent that suddenly appeared between last week and the week before. All was fine and then *boom* the material separated.

Now... alcantrara or just regular oem-like fabric?


Sent from my iPhone using Tapatalk
 

eurocars

5/17/15 - Never forget
Location
Indianapolis
Ride
2006 GTI
Had an issue with the gears locking up on the trans so I took it apart again to investigate. One of the brass pads on the steel fork was hitting the inside of the case, partially locking one of the gears and not allowing the two halves of the case to fully seat. Shaved the pad down with a file and everything rotates freely


 

eurocars

5/17/15 - Never forget
Location
Indianapolis
Ride
2006 GTI
Pulled the old trans to swap it out with the new one. Also pulled the oil pan because i saw some assembly lube on one corner of the pan. Evidently i didn’t do the best job sealing it up. Fel-pro makes an oil pan gasket for the 1.8t that fit great after i modified it some. Also finally made myself a fuel pump controller extension harness since i was finishing up some for other people. The fuel pump controller now sits under the front passenger seat on the floor instead of under the rear bench seat





 

eurocars

5/17/15 - Never forget
Location
Indianapolis
Ride
2006 GTI
Finished making a new mounting bracket for my oil and coolant lines. The old mount i made wasn’t great and i didn’t want the lines rubbing on anything causing leaks. All lines are now wrapped and p-clipped. I added DEI to the mounting brackets and knock sensor connectors that i relocated to the rear of the block.

All hardware checks are done and all bolts marked once torqued. Engine is back in the bay, finishing the rest of the install later this week. Still need to loom the back section of the engine harness but i want to test drive it before it’s all sealed up, so the back half is wrapped in black fabric tape



 

eurocars

5/17/15 - Never forget
Location
Indianapolis
Ride
2006 GTI
Finished making my oil cooler lines and picked up one of the TT axles locally (still need to source passenger side). It is about an inch longer than the GTI axle. Stock ones didn’t even come close to fitting

 

eurocars

5/17/15 - Never forget
Location
Indianapolis
Ride
2006 GTI
Added a battery cutoff switch for peace of mind. Mounted it under the drivers side trim panels.




Also whipped up a quick fuel pump harness to manually turn the pump on from a jump box. Figured the new engine probably wouldn’t like 4 year old gas. Have 15 gallons to pump out



 

eurocars

5/17/15 - Never forget
Location
Indianapolis
Ride
2006 GTI
AEM 340 pump is dead on arrival. It runs for 5 seconds then barely pushes a tiny stream of fuel. AEM only has a one year warranty and i bought it a year and a half ago but just tried it out. Any suggestions for other LPFPs? I bought that one because it was E85 compatible
 

eurocars

5/17/15 - Never forget
Location
Indianapolis
Ride
2006 GTI
Got the new dogbone mount installed tonight (old BSH is for sale in the classifieds if interested). Probably more NVH especially with the VWR puck.



Ordered a 42DD shift cable bracket to try and support the cables and keep them off the exhaust. 42DD said it would fit with the OEM metal cable bracket but it’s way off



Also started on the alignment since it has a TT rack. Used whatever i could find to lock the wheel

 

eurocars

5/17/15 - Never forget
Location
Indianapolis
Ride
2006 GTI
I put a VWR puck in my car too. That APR dog bone does look pretty nice.
I bought it because of the spherical bushing. I wanted some articulation in the mount, whereas the BSH one didnt have enough due to the design. BSH would have probably been fine if the dogbone and subframe bushings were still softer rubber/poly but I didnt want to risk cracking the case under hard acceleration/launches
 

eurocars

5/17/15 - Never forget
Location
Indianapolis
Ride
2006 GTI
AEM pump wasn’t dead, it was pumping fuel out of the basket faster than it could fill it. Drilled 6 holes and it should be much better.

TT axle on the passenger side didn’t fit at all (DSG vs 6MT). Printing an axle spacer to test fit


 
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