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Sean's CatD fixer mk4 r32


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#1
SeanyB

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Ok, so as a lot of you on here already know, my beloved R32 was involved in a very short lived session of destruction derby with a concrete barrier little over a month ago.
After long thinking long and hard about what I was to do with the Insurer's decision not to repair her, I decided to have her back from them and do the work myself.

I really want to put up a thread of the damage she suffered and work I've done to her in the last week since I've had her back.

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This is how she looks now at the end of today :)
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the wing I'm not happy with.....its definitely a darker tone to the rest :/
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Left to do is sort out the drivers door and wing mirror and rear arch.
Alloys will go in for a refurb at a later date.

2 issues have popped up since I've been able to put her back on her 4 wheels.
After been driven 100 yards the ESP lights comes on and stays on..... I have a bad feeling the rear differential system may have been knackered somehow due being towed on just her rear wheels 40-50 yards.
Could that be a possibility?

Also.... the passenger side door has picked up a fault some how as the puddle light stays on and the open door light stays on, on the dash even when the door is definitely shut. And even locked :(
Could this be a sensor?

2003 DPB 3 door - KW V3 suspension coilovers - ceramic coated EFR borgwarner 7670 turbo - ceramic coated HPA turbo manifold & downpipe - AEM boost controller - poly bushed Neuspeed antiroll bars - Neuspeed short-shifter with solid bushings - K&N typhoon induction - RS4 conrod bearings - HPA haldex controller - full stainless Miltek non-res exhaust (decat / 200 cell) - Franko's customer full FIS cluster -  auto headlights - illuminated door handles & wing mirrors - footwell leds - full bora illuminations - VEI gauges ( fuel pressure, oil temperature, air intake temperature) interior & exterior JCAP caps black anodised -

My MK4 R32 story part 1 - CatD repair          My MK4 R32 story part 2 - DIY turbo build

 

 


#2
PaulW

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Top work fella. Can't be much left to do,?

:)


#3
cuprabob

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Also.... the passenger side door has picked up a fault some how as the puddle light stays on and the open door light stays on, on the dash even when the door is definitely shut. And even locked :(
Could this be a sensor?


Probably door module. Common problem amd plenty.of threafs about it on the forum.

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#4
SeanyB

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Probably door module. Common problem amd plenty.of threafs about it on the forum.

https://www.r32oc.com...ent-part-found/


Thanks Bob! :) was thinking it might be that..... could it be a lose connection with anything? As its literally happend today..... I think I may have tried shutting the door when the latch on it was already closed for some reason somehow causing the door to bounce back.
No visual damage I can see, just thinking something may have come loose.

2003 DPB 3 door - KW V3 suspension coilovers - ceramic coated EFR borgwarner 7670 turbo - ceramic coated HPA turbo manifold & downpipe - AEM boost controller - poly bushed Neuspeed antiroll bars - Neuspeed short-shifter with solid bushings - K&N typhoon induction - RS4 conrod bearings - HPA haldex controller - full stainless Miltek non-res exhaust (decat / 200 cell) - Franko's customer full FIS cluster -  auto headlights - illuminated door handles & wing mirrors - footwell leds - full bora illuminations - VEI gauges ( fuel pressure, oil temperature, air intake temperature) interior & exterior JCAP caps black anodised -

My MK4 R32 story part 1 - CatD repair          My MK4 R32 story part 2 - DIY turbo build

 

 


#5
PaulW

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Being towed that distance wouldn't kill a diff.

Get it on VCDS to see

:)


#6
SeanyB

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Being towed that distance wouldn't kill a diff.

Get it on VCDS to see


Got a friend coming round later with a Vag reader to see if that tells me anything.
Will have to book her into a garage for VCDS diagnosis sometime next week if I can as i don't have access to one.

Could an ABS sensor do this? Maybe the driveshaft with hub I sourced could have a dodgy sensor

2003 DPB 3 door - KW V3 suspension coilovers - ceramic coated EFR borgwarner 7670 turbo - ceramic coated HPA turbo manifold & downpipe - AEM boost controller - poly bushed Neuspeed antiroll bars - Neuspeed short-shifter with solid bushings - K&N typhoon induction - RS4 conrod bearings - HPA haldex controller - full stainless Miltek non-res exhaust (decat / 200 cell) - Franko's customer full FIS cluster -  auto headlights - illuminated door handles & wing mirrors - footwell leds - full bora illuminations - VEI gauges ( fuel pressure, oil temperature, air intake temperature) interior & exterior JCAP caps black anodised -

My MK4 R32 story part 1 - CatD repair          My MK4 R32 story part 2 - DIY turbo build

 

 


#7
PaulW

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Got a friend coming round later with a Vag reader to see if that tells me anything. Will have to book her into a garage for VCDS diagnosis sometime next week if I can as i don't have access to one. Could an ABS sensor do this? Maybe the driveshaft with hub I sourced could have a dodgy sensor


Abs fault comes up with the abs light and traction control together.

It could be your steering angle sensor G85

:)


#8
SeanyB

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Abs fault comes up with the abs light and traction control together.

It could be your steering angle sensor G85

I'll check it out..... where is this sensor?

2003 DPB 3 door - KW V3 suspension coilovers - ceramic coated EFR borgwarner 7670 turbo - ceramic coated HPA turbo manifold & downpipe - AEM boost controller - poly bushed Neuspeed antiroll bars - Neuspeed short-shifter with solid bushings - K&N typhoon induction - RS4 conrod bearings - HPA haldex controller - full stainless Miltek non-res exhaust (decat / 200 cell) - Franko's customer full FIS cluster -  auto headlights - illuminated door handles & wing mirrors - footwell leds - full bora illuminations - VEI gauges ( fuel pressure, oil temperature, air intake temperature) interior & exterior JCAP caps black anodised -

My MK4 R32 story part 1 - CatD repair          My MK4 R32 story part 2 - DIY turbo build

 

 


#9
PaulW

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I'll check it out..... where is this sensor?


In your steering wheel. It detects where the wheels are in relation to steering. This could of been knocked out a bit.

Easy enough to rectify if it is that

:)


#10
SeanyB

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In your steering wheel. It detects where the wheels are in relation to steering. This could of been knocked out a bit.

Easy enough to rectify if it is that


Ahh ok! I take it a VCDS would tell you this?
I guess this could be the case with changing the steering rack

2003 DPB 3 door - KW V3 suspension coilovers - ceramic coated EFR borgwarner 7670 turbo - ceramic coated HPA turbo manifold & downpipe - AEM boost controller - poly bushed Neuspeed antiroll bars - Neuspeed short-shifter with solid bushings - K&N typhoon induction - RS4 conrod bearings - HPA haldex controller - full stainless Miltek non-res exhaust (decat / 200 cell) - Franko's customer full FIS cluster -  auto headlights - illuminated door handles & wing mirrors - footwell leds - full bora illuminations - VEI gauges ( fuel pressure, oil temperature, air intake temperature) interior & exterior JCAP caps black anodised -

My MK4 R32 story part 1 - CatD repair          My MK4 R32 story part 2 - DIY turbo build

 

 


#11
Bobobahia

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Great work, really impressed that you rescued it
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#12
Zig

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Glad you got it all sorted mate!!
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#13
SeanyB

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Ok, with borrowing a mates Vagreader, its found 3 fault codes.

2 of which are from the engine section, something about incorrect/restricted airflow! ? Anyone have any ideas tp whys its throwing this up?

And a further 1 more code under the ABS section with the G85 steering angle sensor.
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2003 DPB 3 door - KW V3 suspension coilovers - ceramic coated EFR borgwarner 7670 turbo - ceramic coated HPA turbo manifold & downpipe - AEM boost controller - poly bushed Neuspeed antiroll bars - Neuspeed short-shifter with solid bushings - K&N typhoon induction - RS4 conrod bearings - HPA haldex controller - full stainless Miltek non-res exhaust (decat / 200 cell) - Franko's customer full FIS cluster -  auto headlights - illuminated door handles & wing mirrors - footwell leds - full bora illuminations - VEI gauges ( fuel pressure, oil temperature, air intake temperature) interior & exterior JCAP caps black anodised -

My MK4 R32 story part 1 - CatD repair          My MK4 R32 story part 2 - DIY turbo build

 

 


#14
PaulW

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Ok, with borrowing a mates Vagreader, its found 3 fault codes. 2 of which are from the engine section, something about incorrect/restricted airflow! ? Anyone have any ideas tp whys its throwing this up? And a further 1 more code under the ABS section with the G85 steering angle sensor.


Knew it! I've got a guide up on how to fix the g85

:)


#15
SeanyB

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Knew it! I've got a guide up on how to fix the g85

Awesome stuff! do you have a link Paul?
My mate seems to think with the traction light on it would fail an Mot.... is this correct?
It only seems to come on when you move it 10...20 yards from first initial start off.
Goes away if you're stationery, turn it off and back on again.... drive a further 20 yards and bam, she comes back on

2003 DPB 3 door - KW V3 suspension coilovers - ceramic coated EFR borgwarner 7670 turbo - ceramic coated HPA turbo manifold & downpipe - AEM boost controller - poly bushed Neuspeed antiroll bars - Neuspeed short-shifter with solid bushings - K&N typhoon induction - RS4 conrod bearings - HPA haldex controller - full stainless Miltek non-res exhaust (decat / 200 cell) - Franko's customer full FIS cluster -  auto headlights - illuminated door handles & wing mirrors - footwell leds - full bora illuminations - VEI gauges ( fuel pressure, oil temperature, air intake temperature) interior & exterior JCAP caps black anodised -

My MK4 R32 story part 1 - CatD repair          My MK4 R32 story part 2 - DIY turbo build

 

 


#16
PaulW

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Awesome stuff! do you have a link Paul? My mate seems to think with the traction light on it would fail an Mot.... is this correct? It only seems to come on when you move it 10...20 yards from first initial start off. Goes away if you're stationery, turn it off and back on again.... drive a further 20 yards and bam, she comes back on


No, cars don't fail with orange lights on the dash only reds.

I'll find it tomorrow I'm on ForumRunner :-( it's a 10 minute job to sort but you need full VCDS

:)


#17
SeanyB

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I think I found your thread :)

Whats "the basic setting" procedure?

2003 DPB 3 door - KW V3 suspension coilovers - ceramic coated EFR borgwarner 7670 turbo - ceramic coated HPA turbo manifold & downpipe - AEM boost controller - poly bushed Neuspeed antiroll bars - Neuspeed short-shifter with solid bushings - K&N typhoon induction - RS4 conrod bearings - HPA haldex controller - full stainless Miltek non-res exhaust (decat / 200 cell) - Franko's customer full FIS cluster -  auto headlights - illuminated door handles & wing mirrors - footwell leds - full bora illuminations - VEI gauges ( fuel pressure, oil temperature, air intake temperature) interior & exterior JCAP caps black anodised -

My MK4 R32 story part 1 - CatD repair          My MK4 R32 story part 2 - DIY turbo build

 

 


#18
IainR32

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Not so hard to put right in the end ?

#19
PaulW

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I think I found your thread :) Whats "the basic setting" procedure?


You need to see how many degrees your steering is out by. That's done on VCDS.

If it's minus then turn the wheel left hand down if it's + then right hand down.

Someone with VCDS can check for you

:)


#20
DougalR

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Excellent work man! good choice in fixing it, Insurance company didnt get rip you off. An R saved from the breakers is always
a good thing!

How long did it all take you put her right dude??

May the boost be with you

.:Rotrex powered sleeper...well sort of.... :)
You can only plan so far.....After that, well you have to take a few leaps of faith.......


#21
IainR32

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Have you had alignment done? If not that can do this if it's so far out of alignment

#22
PaulW

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Have you had alignment done? If not that can do this if it's so far out of alignment


That won't switch the light off.

The lights on because the steering wheels doesn't know what angle the wheels are at.



:)


#23
SeanyB

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Not so hard to put right in the end ?


Ahh mate..... I did all the work but the spraying on my own! lol! There were a few moments I just wanted to kick the car off the axle stands and spit at it lol!
Mainly once noticing I had split the power steering line dropping and taking out the subframe.
And with the amount of time I twatted me head being under the arch hour after hour.
i'm hoping to get her in for a 4 wheel alignment and an Mot tomorrow.
That will tell me if shes working all good as she should :)

You need to see how many degrees your steering is out by. That's done on VCDS.

If it's minus then turn the wheel left hand down if it's + then right hand down.

Someone with VCDS can check for you

Ok Paul, might have to be the local VW as I know no one with a VCDS.

Anyone from this forum in my area on that might have one? (high wycombe)


Excellent work man! good choice in fixing it, Insurance company didnt get rip you off. An R saved from the breakers is always
a good thing!

How long did it all take you put her right dude??


Yeah man.... thought long and hard and almost passed it up. a few people on here convinced me to do so, and I'm glad :)
Hmmm, all of this week really, working it around work and stuff :)
Share a place with a landlord with a daddy of all garages in the back yard! Name any tool, he's got it! Apart from the stupid M10 bolt needed to take off the drive shaft.
spent £28 in Halfords buying a set to source the tool needed to do the job.
He even has a pit in it! :)

Have you had alignment done? If not that can do this if it's so far out of alignment

Alignment will be done tomorrow hopefully. If this doesn't correct the issue as Paul says, ill take it to Vw to sort out.

2003 DPB 3 door - KW V3 suspension coilovers - ceramic coated EFR borgwarner 7670 turbo - ceramic coated HPA turbo manifold & downpipe - AEM boost controller - poly bushed Neuspeed antiroll bars - Neuspeed short-shifter with solid bushings - K&N typhoon induction - RS4 conrod bearings - HPA haldex controller - full stainless Miltek non-res exhaust (decat / 200 cell) - Franko's customer full FIS cluster -  auto headlights - illuminated door handles & wing mirrors - footwell leds - full bora illuminations - VEI gauges ( fuel pressure, oil temperature, air intake temperature) interior & exterior JCAP caps black anodised -

My MK4 R32 story part 1 - CatD repair          My MK4 R32 story part 2 - DIY turbo build

 

 


#24
IainR32

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That won't switch the light off.

The lights on because the steering wheels doesn't know what angle the wheels are at.


From experience on later vw audi if the alignment is out the light goes on, get it aligned take it for a drive or lock left to right to calibrate and the light goes out

#25
SeanyB

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Does anyone on here no what those other fault codes are about with the secondary air injection?

From experience on later vw audi if the alignment is out the light goes on, get it aligned take it for a drive or lock left to right to calibrate and the light goes out


I've read this from an audi forum http://audisrs.com/v...188&start=0
Is this what you're talking about?

2003 DPB 3 door - KW V3 suspension coilovers - ceramic coated EFR borgwarner 7670 turbo - ceramic coated HPA turbo manifold & downpipe - AEM boost controller - poly bushed Neuspeed antiroll bars - Neuspeed short-shifter with solid bushings - K&N typhoon induction - RS4 conrod bearings - HPA haldex controller - full stainless Miltek non-res exhaust (decat / 200 cell) - Franko's customer full FIS cluster -  auto headlights - illuminated door handles & wing mirrors - footwell leds - full bora illuminations - VEI gauges ( fuel pressure, oil temperature, air intake temperature) interior & exterior JCAP caps black anodised -

My MK4 R32 story part 1 - CatD repair          My MK4 R32 story part 2 - DIY turbo build

 

 


#26
IainR32

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Does anyone on here no what those other fault codes are about with the secondary air injection?


I've read this from an audi forum http://audisrs.com/v...188&start=0
Is this what you're talking about?


Yeah not worked that deep on mk4 r32 was just an idea mate

#27
SeanyB

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Yeah not worked that deep on mk4 r32 was just an idea mate

Yeah man..... its all appreciatated! I think this method, is the one Paul is on about....you need a VCDS to calibrate the steering wheel.

2003 DPB 3 door - KW V3 suspension coilovers - ceramic coated EFR borgwarner 7670 turbo - ceramic coated HPA turbo manifold & downpipe - AEM boost controller - poly bushed Neuspeed antiroll bars - Neuspeed short-shifter with solid bushings - K&N typhoon induction - RS4 conrod bearings - HPA haldex controller - full stainless Miltek non-res exhaust (decat / 200 cell) - Franko's customer full FIS cluster -  auto headlights - illuminated door handles & wing mirrors - footwell leds - full bora illuminations - VEI gauges ( fuel pressure, oil temperature, air intake temperature) interior & exterior JCAP caps black anodised -

My MK4 R32 story part 1 - CatD repair          My MK4 R32 story part 2 - DIY turbo build

 

 


#28
IainR32

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Yeah man..... its all appreciatated! I think this method, is the one Paul is on about....you need a VCDS to calibrate the steering wheel.


Probably with it been older ecu

#29
SeanyB

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Ok so she flew through the Mot today with absolutely no issues :) a very happy chappy!
She had the tracking done also, which the mechanic said only needed a very slight adjustment. She drives straight and true just like she used to :) no knocking, juddering, rubbing, pulling or anything of that kind.
Tracking didn't fix the G85 steering angle sensor though, so shes booked in Vw high wycombe friday to have her door module replaced along with recalibration of the steering wheel and investigation/diagnosis of the secondary air injection.

Big thumbs up!!! :)

2003 DPB 3 door - KW V3 suspension coilovers - ceramic coated EFR borgwarner 7670 turbo - ceramic coated HPA turbo manifold & downpipe - AEM boost controller - poly bushed Neuspeed antiroll bars - Neuspeed short-shifter with solid bushings - K&N typhoon induction - RS4 conrod bearings - HPA haldex controller - full stainless Miltek non-res exhaust (decat / 200 cell) - Franko's customer full FIS cluster -  auto headlights - illuminated door handles & wing mirrors - footwell leds - full bora illuminations - VEI gauges ( fuel pressure, oil temperature, air intake temperature) interior & exterior JCAP caps black anodised -

My MK4 R32 story part 1 - CatD repair          My MK4 R32 story part 2 - DIY turbo build

 

 


#30
r32maco

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Great news :)
.:R32 mk4, Shiney & Slammed




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