Bora R32 Build Thread

[beale187]

Pulled the dash out of the R32 (identical to the Bora dash, same part no.)




Bora dash, note huge crack from airbag.


R32 dash, schmick!


Epic job.

[sports racer]

Thanks for sharing but glad it was you doing all this not me.

[beale187]

Here's how it sits now. Everything replaced, wired up and good to go!

[jmcc]

wow, good as new, looks clean, nice!

[beale187]

Well here we go again....
After a few weekend's on the tools and a brief game of "musical MK4's" the R32 engine is finally out!







All the steps involved mentioned in prior pages for removing the BDE engine were identical for the R32. With the exception of these 2 items.

Vaccuum Line for Exhaust Flapper


AND, the Secondary Radiator


Undecided what to do with both at the moment but that's a problem for another day.

Whilst the R32 engine is out I'll be doing chains/guide and clutch. So I'll start stripping the engine down over the next couple of weeks.

[IanPGonzaga]

Moving on nicely with things there Mr B!

[beale187]

Engine is getting stripped down, ready for clutch, chains and guides.



Definitely in need of a new clutch! This was it at about 150,000kms.


Whilst I wait for those bits to arrive thought I'd turn my attention to something that was bugging me. Apparently the previous owner or their mechanic had no idea how VAG electrical connectors work . 4/6 coil plug were completely destroyed along with one injector plug. So it was swap them out



So I grabbed the loom from the BDE Engine armed with my eBay tools and got to work.


Replacing Coil connector (P/N 1J0973724)

Slide the purple retainer to the side


Remove the connector cover


Insert ebay Tool (3mm) into top and bottom and push down till it clicks.


Pull out terminal wire from the back.


Repeat x4.. LH R32 connector (the terminal block actually snapped off this connector. Not sure if it was just brittle or I wiggled the terminal tool and snapped it meh..), RH Bora BDE V6 connector. Same p/n though. Installation in reverse.


Next time to replace the injector plug (P/N 06A973722)

Lift the purple retainer up and out.


This one was a little tricky to get a pic of but there is a small black clip on the inside which needs to be pryed up.


Then just pull it out from the back. Installation in reverse.

[beale187]

* REMOVING THE SUBFRAME, SUSPENSION, P/S RACK, SWAY BAR - R32*

Back to it over the weekend.

First step, disconnect the steering column from the rack.

Remove the deadpedal


Unbolt 13mm bolt from steering column universal joint


Remove headlight level sensor from chassis




Now onto the Brakes, these are eventually going on the Bora.

Disconnect brake pad wear sensor



disconnect ABS sensor


Pull away ABS sensor wiring away from strut.




Remove brake line plastic shield and line clamp and remove from strut. Remove 2x 19mm brake carrier bolts and wire tie brake assembly to body of the vehicle.





Undo 2x 21mm strut nuts (impact required or strut socket)



Not necessary but as I was doing it solo i used some elastic straps to tie up the struts so they wouldn't just fall forward when lowering the subframe.



Undo 4x subframe bolts (24mm from memory and they are TTY, replace with new according to VW)




Lastly, 2x 13mm O2 sensor wiring shield at the rear of the subframe


Then all that's left is to lower that bad boy down.





DONE! I'll give it a clean up then bolt it up to the Bora.

[IanPGonzaga]

woop woop - nice progress!

[beale187]

Pulled the .:R subframe out on the weekend gave it a quick clean up before the install and got it all fitted up. Will need to replace the bolts at some stage as they're one-time use and get torque'd to 100nm +90




Struts to body were 60nM


Also got around to fitting the front brakes as part of that, they'll need new fluid but that's a little hard to do with being able to cycle the ABS pump. Found that I had to swap out the front brake lines to match the R32 calipers, they were slightly different between the 4motion and R32. Lastly carriers to hub were 125nM (little loctite if they look worse for wear).



different in 4motion (right) brake lines V R32 (left)






Next up, rear shocks and springs!