[franko180]

Not very exciting, just a few pics of some of the parts sourced to go in with the engine and other bits I collected.

Yes that's snow around the car

Gearbox, transfer box, standard S3 cats, standard S3 downpipe (I sold the downpipe and cats and went for PipeWerx 3" sports cat and downpipe)


Standard S3/TT cat, not sure why I put this here as it was sold to a TT owner


More goodies: Twin S3 intercoolers, Seat Leon Cupra R centre boost pipe (I think this was chosen as it mounted a bit better for clearance than a S3/TT one and may have been a bit lighter also), plus a pair of US spec rear lights which I was in the right place at the right time to grab.


Had to dump some of it in the hallway of my house that I Was still in the middle of doing up, so had a lot on at this time, car in bits, house in bits.


Some of the parts outside getting a quick clean up


They cleaned up ok but then lived in the porch for a bit (which was also going to be done up) with the hallway/stairs.


A bit more cleaning








Was glad to source all the pipe work that the caveman breakers had cut off the 1.8T.

 

[franko180]

A bit more then...

So the 1.8T needs an intercooler, or in this case intercoolers. To get the car up and running I was sticking with standard twin side mounted intercoolers the same as the Audi S3 8L. The S3 and the TT have factory installed vents in the wheel arch liners to encourage air to pass from the intercoolers and to vent it from around their area to try to keep the temperatures down.

There is an option to use an OEM vented arch liner (part number 1JM809962A) from the Mexican "Citi" Golf "Mk 4.5" but there is only one side available and it would still need a bit of hacking to fit my car, so I chose to DIY them. So I got hold of a couple of S3 arch liners and set about cutting/chopping the vents out and fitting them to the R32's arch liners. They don't look pretty on the inside of the arch liner (engine side), lots of glue etc for strength, but you never see that, they look good enough on the 'wheel' side of the arch liner. I've seen all sorts of worse bodges than these in the past, including using home air brick ventilation covers from B&Q

Original ditched arch liners from this R32's apparent previous "country life"


S3 arch liners ready for the chop


Chopped


Making a template for cutting the R32 liners


Cutting


Result


More to come..

 

[VR6Rich]

Nice work, I've considered the Mexican vented arch liner mod for my oil cooler but decided to run it in the centre now.

Sure I read somewhere there was a vented arch for both sides.

 

[franko180]

Nice work, I've considered the Mexican vented arch liner mod for my oil cooler but decided to run it in the centre now.

Sure I read somewhere there was a vented arch for both sides.

Cheers Rich, I didn't see there was an opposite side available as I thought the Citi Golf mk4.5 only had a fairly ordinary single SMIC similar to any 1.8T mk4? Didn't mind making them anyway, saved a few pennies for a couple of hours work.

 

[franko180]

Small update then..

So the engine bay was being prep'd by Gaz at VACS. The heatshield is different on a 1.8T K04 to an R32, plus he had to install air conditioning pipes and other pipes prior to the engine being installed, he did a brilliant job on this, looking like an OEM factory spec install. I didn't really get photos of it, it's easy to forget to take them with everything going on. Of course the ECU was also installed and the engine side wiring loom also. The twin intercoolers were mounted and their ducting, some reworking was done for this and also learned that because of where some of the OEM S3 pipework sits behind the headlight, it means I couldn't fully use the R32 DSG air intake frame. We could use the larger DSG snorkle into the standard airbox but not the entire kit as the boost pipe with the map sensor fouls on it behind the headlight. Gaz also made sure he did some extra work to make sure the extra water pump that the S3/TT 1.8T has was installed. This little pump runs for a few minutes after the engine is turned off to pump coolant around to help cool things down. There were lots of little bits such as that going on that at this stage that I've probably forgot.

Arch liners (not so pretty from the inside view but it can't be seen usually), xenon headlights and other bits loaded into the soon to be retire 1.8T daily for transporting to Gaz.


The R32 was now at Gaz's garage for prep for the engine installation. The front wings were removed to swap with my 1.8T's eventually because they were in better shape


The S3 boost pipe behind the headlight, new Bosch battery


SMIC ducting test fit, OEM design to channel cold air in. These and the radiators/pipework were all test fitted and any adjustments were made prior to the engine going in.


Engine installation not far off.

 

[AMV]

Always a good read

 

[franko180]

Always a good read

Cheers geezer

 

[franko180]

A little update about the engine prep.

A view (through the adaptor for the Badger 5 supersize TIP) of the K04 turbo, really nice clean turbo, showing how relatively 'young' this engine was/is.


Pipewerx 3" downpipe mounted up, though somehow I forgot to photo the 3" sports cats I also got with it.


I think at this moment the Engine prep was just about complete. All the hoses the cavemen breakers chopped were replaced, the Forge silicon hoses were fitted, Badger 5 TIP fitted, a new clutch (just as a precaution), oil / filter, 4 spark plugs. That dodgy bit of broken plastic near the dipstick that covers some breather hoses also got replaced later with a fresh OEM item.


Engine soon to be in it's new home.

 

[DaleM]

Great build thread, slightly disappointed with the choice of engine though

 

[franko180]

Great build thread, slightly disappointed with the choice of engine though

Can see that point of view, this is the R32OC and a place for the V6 howl, not so much 4 cylinder blandness

It wouldn't have made any sense for me to put a 3.2 in it as this is not the only car I have and I've already got some 3.2 BFH action.. An R36 would have been nice but a lot of faffing with the electronics / CAN bus and expense for not that much gain. A 2.0 TFSI would have been interesting but needs custom work and would still be 4 cylinder, I know they can make decent power, but it's a daily in the end, it's not going all out. 1.8T was the path of least resistance and the engine was a fairly "late" 2004 unit with only 29k on it.

I'll do some speed testing eventually 3.2 vs 1.8T, a bit of a strange thing to compare as their character and power delivery are so different and they won't be tuned the same or have the same bolt ons, but can try some 0-60, 0-100, 30-70 comparisons, just curiosity more than anything.

 

[franko180]

So I have a full FIS cluster in my Bora V6 and had a similar one in the daily AUQ GTi so there was no way I could stomach looking at a half FIS display in the R32. The design of the cluster is nice enough but that tiny trip computer display looks a bit dated to me.

So I had got hold of an Ebay full FIS cluster display board, did some testing and surprise surprise, the now common issue surfaced - faded centre display. Lots of Ebay / Facebook clowns sell Golf / Bora clusters without testing them properly and bringing them up to temperature and most now days have some fade due to age. Some have missing lines similar to the well known TT issue, but normally on MK4 clusters it's a fade issue.








Only one thing for it, was to replace the centre LCD. So, cluster stripped:


LCD removed:


LCD fitted:


Tested ok and looking 100% better:




I didn't want to customise the cluster too much (some people go wild changing LED colours etc, but that's not for me) but I do prefer the older thicker style Bora Sport needles, so I took a spare set, removed the black caps and painted them silver (so I didnt butcher the original needles and still have them). The older needles are thicker and illuminated on all sides.


Standard R32 half FIS ready for conversion


R32 full FIS with the custom needles nearly built.


Initial test in the car


Comparison, half FIS to full FIS



Lit needles


Angled view of the Bora Sport needle(s) that I put in that I prefer to the skinny standard needles.


It was around this time that it was time to let go of my daily 1.8T, the insurance was due and with the R32 project going to be ready fairly soon I switched over to driving the Bora V6 for a while. It's never a chore to switch over to the Bora, its far from a standard car itself.


So as for my departing daily, 10 years (!) of driving, 209,226 miles, original engine (stage 1 mapped), gearbox, clutch, turbo. Great car and could still return way over 40 MPG on longer runs. Was sad to see it go, but hopefully greater things to come from the R32 1.8T




As a side note to this, if anyone is interested I can help with cluster upgrades / coding / installation. I often have spare half FIS / full clusters (even petrol / diesel / Golf / Bora sport / R32) and can also do FIS screen replacements as shown above. Can convert half FIS cars to full FIS and fully install / code back into the car. I should be putting an update later in the thread to show a bit more why I prefer full FIS clusters.

 

[franko180]

PS if anyone sees BL03 ERV I'd be interested to hear what mileage it's on, I sold it to a trader (foreign) and it was such a clean car with no faults, I wouldn't be surprised if they clocked it back to make a profit on it and binned some of the history.

 

[ClintonB]

Neat job on the cluster. Always a sad day when you see your trusted vehicle go. hopefully, you get many more happy memories with the latest "daily". Nothing wrong with the BDF engine. Have had the TT 225 for over 10 years, 230 000 miles on the clock and still runs lovely, wife and kids have taken it over and seem to enjoy it.
All the best with getting this the way you want it.
Very nice read.
Cheers
Clinton

 

[MIQ]

It's amazing you saving this car , what is the reg of you don't mind me asking as I remember a mk4 near me that always had dogs in it

 

[annavr6]

Cool thread, so glad you have rescued it from scrap, even if you are putting a 1.8T in. I hope my lupo can make that mileage on your old one, 173 at the moment

 

[franko180]

Cool thread, so glad you have rescued it from scrap, even if you are putting a 1.8T in. I hope my lupo can make that mileage on your old one, 173 at the moment

Thanks, it was a lucky find, it was just the car I was looking for, I think I was lucky and so was the car as I think it would have been finished off and crushed if I hadn't taken it. What engine is in your Lupo, are they known for going the distance?

 

[annavr6]

Thanks, it was a lucky find, it was just the car I was looking for, I think I was lucky and so was the car as I think it would have been finished off and crushed if I hadn't taken it. What engine is in your Lupo, are they known for going the distance?

Its the 1.4 TDI 3 cylinder, Dont think the petrols go that high but i have not yet come across a TDI lupo this high as there isnt many around. Ive had it 9 years. I think being used daily has helped keep it going too, nothing to sieze and keeping the battery alive and obv an oil change every 10K. hoping it will make 300K one day

 

[franko180]

Its the 1.4 TDI 3 cylinder, Dont think the petrols go that high but i have not yet come across a TDI lupo this high as there isnt many around. Ive had it 9 years. I think being used daily has helped keep it going too, nothing to sieze and keeping the battery alive and obv an oil change every 10K. hoping it will make 300K one day

I bet it'll be fine, if the engine ever breaks I'd be tempted to get a mk4 ASZ 130 into it, would be able to really shovel with the low weight and that grunty engine. Or ignore me, guess I've got a fetish for engine transplants

 

[franko180]

Talking of engine transplants, the 1.8T was getting installed and the front wings (which were robbed from my departed GTi) were fitted. At this point it was a matter off getting the slam panel/radiators back on and piped up.

I did ask MK4 guru Ray (aRd) to get involved a bit earlier in the build, regarding the immobiliser/cluster/keys etc, which was helpful, but we couldn't get the cluster/keys matched to the Audi S3 ECU, so we had to do the classic engine transplant "cop out" and defeat the immobiliser to get the car to run. This issue was something to come back to later.


During this time I was still doing bits and pieces away from the car. Did a deal with Gaz Jones for his redundant standard headlining to replace my original sagged item, so one more part of the jigsaw sorted. Headlining was a little bit dirty from storage in the garage and the usual "one thing leads to another" car crazyness kicked off and I decided to take all the headlining bits to be retrimmed.

 

[annavr6]

I bet it'll be fine, if the engine ever breaks I'd be tempted to get a mk4 ASZ 130 into it, would be able to really shovel with the low weight and that grunty engine. Or ignore me, guess I've got a fetish for engine transplants

no i like the idea. it would be a little rocket ship although it would be a bloody tight fit and out of my capabilities of building myself!