Bora R32 Build Thread

[beale187]

Got busy on the weekend swapping over panels, rad support, fan assembly etc just to test fit everything. Still needs adjustment but it's the first time the beast has looked like a car and not a wreck in over a year!

Donor vehicle




Project car




This took WAY longer than it looks. Good 1.5days.

[dylan8]

Looking good. All the new panels in good condition or still need work?

[beale187]

Looking good. All the new panels in good condition or still need work?

Panels are straight, just need paint. Not looking forward to unpicking the bump strip from the bar cover though

[beale187]

REPAIRING THE DAMAGE

Replacing airbags, crash sensors, seat belts and airbag module.

Many busy weekends spent doing this right and as per spec and a few things had to be done that I wasn't expecting unfortunately. Everything done here is as per VW spec. If it said "replace it" it got replaced regardless.

As per VW. If your front airbags deploy you must replace following.
Airbags (der!)
Front Crash Sensors (located under front seats)
Airbag Module (some say it can be cleared, but why risk it)
Passenger Front Airbag Mounts
Drivers Clock Spring
Seat belts (if deployed)

So here we go.

Started by replacing the seat belts. Firstly, you'll need to remove your front seats.

Remove Lower Pillar Cover (note tension on seatbelt, deployed and needs to be replaced)


Lift plastic cover undo top bolt. (For installation, torque this bolt to 40nM)


Pry off Upper Pillar Cover and unscrew belt retainer


Lift up rear seat and unscrew sill trim, lift up C pillar trim enough to release sill trim.


Unscrew lower sill trim screws



Begin prying off sill trim. I found it easier to start from the rear and work my way forward. You will also need to lift the small trim on the A pillar to release the sill trim.


Disconnect seatbelt igniter.


Lift carpet and insulation and remove lower bolt (installation, torque 40nM)


Remove seatbelt bolt here (torque 40nM) lift belt up and out of retainer.


And you should be left with this.


Installation is the reverse order.

[beale187]

Next.... whilst the seats are out time to replace the crash sensor.

With front seats removed. Lift carpet and insulation, disconnect crash sensor and unscrew 3x Hex screws.


Replace old for new (old on the right as I scratch the sticker as not to get confused!). They can only be installed in one direction as locating pin prevents any other way.

[beale187]

Now onto Airbag Module which is located towards the firewall under radio.

Remove shifter and boot, push centre of boot forward and lift up.


Lift out ashtray and unscrew hidden torq screw.

Unscrew centre console trim (passenger and drivers sides)




Lift the centre console up starting near shifter boot and pull up and back. The airbag module should now be visible.


Unscrew 3x 10mm nuts and disconnect yellow connector.



Old and New



Installation reverse.

[beale187]

Next onto the drivers airbag.

Rotate steering wheel 90 degrees to expose access hole at rear.





With a flat screwdriver insert and push front screw driver downwards. This will release the springs holding in the airbag and it should just pop off.

Sometimes they're easy. Sometimes they're a mother@&%^er to remove, be patient.



Pull off yellow connector, lift airbag out.

[beale187]

Replacing Clock spring

Remove steering wheel nut. (installation, torque to 55nM)



Steering wheel will now pull off. Before removing though make sure your wheels are straight! Mark wheel and steering column to ensure they all line up when reinstalling. I didn't do this because I'm installing the R32 wheel

remove steering wheel cover trim upper and lower




This will expose the clock spring. Disconnect yellow plug.


Pry off clock spring.


If you're reusing it for whatever reason, cable tie to ensure it does not spin freely as the steering angle sensor is part of the clock spring. New and old


Installation is reverse.

[beale187]

Replacing passenger airbag.

Unscrew airbag dash cover


Unscrew airbag 2x each side.



Slide airbag connector out of retainer and disconnect.


Old and new


Unscrew airbag brackets both sides and replace (2.5nM for installation) note the coloured indicators which show they deformed from airbag deployment (it's an explosion after all!).






Installation is reverse. The airbag dash cover is simply pushed back into place.

[beale187]

If this was a straight up repair, the only thing left to do would be to recode the new airbag module. I'll put steps on that when the time comes.

Unfortunately for me, when I went to put the airbag dash pad back in, it just wouldn't sit right.


Little did I notice when the airbag deployed it completely cracked the underside of the dash. Doesn't look like much from here.


But it meant the whole dash had to be replaced

[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.