Emad's MK4 GTI

[ybkopa]

Good idea in using the early model XR6T intercooler. I used one myself about 10 years ago on my S15 200sx as it was a very cheap upgrade and the intercooler is of pretty good quality for an OEM part (full alloy core and end tanks (none of this plastic end tank crap) and made by Garrett, not to mention about 3x times larger than the stock side mount and in a better position for airflow).

You can pick those XR6T intercoolers for like $50-100 as most owners upgrade to a larger one anyway.

The intercoolers are too small for the XR6 once tuned up, but perfect for a smaller 4 cylinder turbo.

Yeh it's a perfect size, and I picked it up for $50 delivered lol. A great deal when compared to anything else in that price range. Plenty enough for my setup too.

[ybkopa]

Haven't made an update in a while as I wasn't really doing anything other than driving it until a few weeks ago when my water pump decided to die. First time doing a timing belt & water pump job and one that I was really worried about doing myself for a while but I went for it and thankfully I don't have bent valves after the job

Installed a titanium pulley provided by Seb at Euro Revolution because why not.



A few issues that I faced, unfortunately my new OEM serpentine tensioner failed, not sure exactly why but it was shredding the belt. Installed the old tensioner the exact same way and it was working fine.


I also had to replace my radiator fan as it failed but its making a lot of noise, anyone else experienced this?
https://www.youtube.com/shorts/PMWbbm4UHl0

[ybkopa]

The radiator fan noise is no longer present as the noise was coming from the fan hitting part of the wiring loom. Some quick electrical repairs and making sure its tucked away has fixed the problem.


Unfortunately I'm just facing more issues. One of the pulleys was eating into my throttle body piping so I've re-done part of the piping so it goes through the cutout where my washer bottle used to be. Much cleaner although might have to be re-done once I install my xenons.



Some good news though is my Ecumaster Classic has arrived and once I sort out a few more issues and get the car running better it'll be off to get tuned!

[ybkopa]

Haven't updated the thread in a while so thought I'd make a post. Haven't done much other than buy more parts but not install them as I normally do. It's no longer a daily car so it spends most of its time on jack stands waiting for things to be installed or in the driveway

Regarding the kit I was going to run, the GLI front lip just won't work. It is near impossible to fit it to the Golf bumper, might be a crappy fibreglass mould as it has been done before but for some reason there would always be a bulge on both ends and it's too short.



Another set of wheels were recently picked up. SSR Super License A in 17x9 +35 and 17x9 +29. Fitment is near perfect with my 20mm adapters, just needs a bit of camber which should be possible when I install my new suspension setup sometime this week.



I also ordered the whole catalogue of Ultra Racing's braces. The first one to be installed was the strut brace as I would later need it to hold onto the power steering rack when I drop by subframe. Decided to drill into the strut tower holes and install rivnuts instead of using a nut and bolt as they recommend.



I wish I just done a drill and tap instead as I'm having an issue with one of the holes where the rivnut isn't staying and just pops out. I used the same step drill bit but I'll try figure something out.



Also, after a year and a half I finally received my lips for my other set of SSR's that I was rebuilding. Threepiece.us unfortunately drilled a hole into each lip for the valve stem but also still kept the cutout for the original valve stem. Took it to a machine shop and they filled in the holes. Went to mock everything up and realised the fourth lip was made incorrectly and there is 40 bolt holes. This was well over 4 months ago. They realised the issue and claimed they'll get it sorted, but until now I haven't been given a courier connote or anything. Ignoring my emails too which sucks but oh well.

[ybkopa]

The past week has been installing all my suspension bits that have been sitting around for too long.
First thing up was to press in the CSH billet subframe bushes. Recently picked up a shop press and it has been coming in clutch plenty of times. From pressing in new bushes for my subframe, to the dogbone bushes and also pressing in new wheel studs.


Next up was removing the top strut bush and replacing it with the billet adjustable mounts. Although I figured it out and it is fairly simple I couldn't find much resources on how to build it. To save anyone else some time you install the plastic top cap, the OEM bearing goes on top then you install the top strut mount as shown in the picture below.


Also installed some coilover covers to keep it nice and clean as it was already full of sand and dirt and it hasn't seen much street use.


Whilst I wait for my bolt order from Vagparts, I gave the old bolt a quick sandblast to clean it up. The bolt is only temporary to mock everything up until all my bolts come in.


The sandblasting cabinet came in clutch again to clean up the new 312mm carriers and also my calipers which I got painted in Porsche Lizard Green. Here's how it looks assembled. T3 DBA rotors, Bendix pads (until my Project-Mu pads arrive) and the painted calipers.

[beale187]

looking good Emad, what did you think of the coil over cover?

I'm assuming the 312mm front were from a Bora 4mo, yeah?

[ybkopa]

looking good Emad, what did you think of the coil over cover?

I'm assuming the 312mm front were from a Bora 4mo, yeah?

The coilover cover seems pretty good but we'll find out how it is underneath in the future. I know this time when I took it a part there was a lot of crap sitting on the threads.

The carriers were from a TT but I guess they're all the same.

[ybkopa]

It was now time to tackle the rear of the car. First thing up was removing the old hub to install the SPC shims. I decided to go for the -1 camber and -0.5 toe shims. Once I get an alignment sheet I may have to change it but that's just what I thought would work best.


Next up was tackling the brakes. I decided to buy a rear caliper setup from a V5 so the 256mm setup. Although, I also bought the CBAuto S4 300mm conversion. Unfortunately, I messed up as I think for it to work properly it needs the V6 rear caliper. I'm currently just waiting on a reply from Paul otherwise in the mean time I may try using a 6mm thick washer and seeing if that fixes the problem of the rotor hitting the carrier.

[ybkopa]

Audi S4 rear disc conversion is done. It should fill up the wheel much more compared to the stock 232mm disc. MTEC discs arrived pretty quickly from the UK and they will re-drill them much cheaper compared to the quotes I got from local engineering shops.



Next up was tackling some of the vacuum leaks I had. In this case the brake booster line which is a very common piece to leak as it is plastic. I had previously silicone taped it but cutting off the broken section and replacing it with some rubber hose is much better and won't leak.


I decided to change things up as well with my valve cover and got it re-painted in the same colour as my brake calipers - Porsche Lizard Green. I took the opportunity to install the Integrated Engineering AN fittings in preparation for my catch can install which I'll be doing soon.
Finished it off with some titanium nuts supplied by Euro Revolution.


Not much left to-do before I can start driving it again -- until I decide to put it back on halt for more upgrades

[beale187]

Love the rear conversion Emad, the 256mm disc look so puny under 18's. How'd you go with the carriers? Shim them? or source V6 ones?

Did you have to adjust / relocate the handbrake cable?