New ride: '02 MK4 GTI

[Camaroo12]

Very nice one

[leighaus]

So over yesterday and a bit today, i did:

Fuel filter
oil and filter change
spark plugs (colder for the tune)
Timing belt kit (ultimate)
Acc belt
Water Pump
Thermostat and housing
pulley upgrade
valve cover gasket kit

All in all, it went pretty smoothly. First time doing a timing belt and it wasnt too bad. didnt take too many photos as theres a few guides floating around. I used: VWVortex.com - Ultimate Timing Belt DIY!!

Jacked her up, ripped off the imported jap wheels,


the task at hand: a lot of **** in the way of a small space


stock pulleys (note the size orientation of the balancer to power steering)


Cover is off. What a bitch that was for no reason. Then it just almost fell off..


whack a 16mm spanner on your acc tensioner, then stuck a 3mm allen key in the locking hole. The acc belt basically falls off.


Mark your old belt at TDC, including orientation.



The infamous engine mount (pictured in the centre).. Constantly in the way, but not too bad.


Stock belt on the left.. One side of the teeth was starting to wear a bit, no cracks at least. And a gates kevlar racing timing belt to the right... It's blue, so you know it's good


The old plastic water pump: Had only just started letting go, which was good Replaced with a german metal impeller.


Tried to bicycle chain the belt on, however ended up successful putting the water pump on last.


the new lightweight pulleys. Note the size orientation has now swapped. Means your engine doesn't have to work as hard to turn your alternator, water pump, etc = free power.


Thermostat housing with thermostat snug in behind. That bottom bolt was a bitch. I'd probably remove the alternator next time. My thermostat was starting to fail to open, so glad i changed this over.


And all re-assembled ! happy days.

[trickysimon]

Someones been busy! Good work!

[dylan8]

Good job tackling yourself. I was too worried about doing it myself on the bora.
Had a chance to drive and notice any difference from the pulleys

[leighaus]

Cheers guys. It's a big job abd a fiddly job, but it's not that hard. I've been swinging spanners on my own cars for a bit over a decade and didn't fond anything too difficult. i was just super anal about getting the timing right

The car feels like its picking up a bit faster and it's running really really smooth. Probably a combo of the pulleys and the different plugs. I'd say maximum 4-5rwkw difference. On my bum dyno.

I'll be taking my car to a real dyno soon and getting the forge wastegate actuator fitted.. so it'll be interesting to see what she pulls

[trickysimon]

Rwkw? You install that commodore diff?

[leighaus]

Slip of the tongue. I've owned a couple of performance rwd cars prior to this and just finished night shift before this job. Brains a bit cloudy

Wish it was awd though, it's no fun when the roads are wet. Have to baby it so much.

[MelbMk4]

beautiful car bro!! very clean and great work!!
hope to see that babe around
take care!!

[leighaus]

thanks mate...

Yesterday replaced the coolant flange (where the temp sensor sits) as it had lost its seal to the block. Nice easy job.

Then drove my newly fixed car to work to have the bloody clutch pedal assembly let go. I can luckily still use my clutch, but it has fallen to the floor a couple of times. Think ill just take it to a workshop and get it done quickly.

[leighaus]

Another ecs order about to hit the front door..
Replacing 3 door lock modules... Bitch of a job ahead!

Pics to follow

[dubster99]

Im waiting for my ecs order too so I can get mine back together! Yet to have a lock module fail as of yet! Touch wood!

[RolfGolf]

Another ecs order about to hit the front door..
Replacing 3 door lock modules... Bitch of a job ahead!

Pics to follow

Best of luck - time consuming and fiddly especially if your doors are unable to be opened.

[blackers10]

how much are they setting you back including postage ??

[kendog]

Hey mate, just a couple of questions on the Door Lock Modules..

I was told that the later model door locks, late '02-'04, didn't speak well with the CCM etc of the earlier model cars, '99-early '02, and so was told not to put newer (although more reliable and quieter) Door Lock Modules in an earlier car, as they have 'issues' with the Control Module.. Anyone else heard that?

Also, did you try the fix/mod where you take the Door Lock Module apart, and re-solder the main contacts on the circuit board inside the module? It has worked for 3 out of 3 of my doors so far!!

Cheers,
K.

[leighaus]

Total price for 3 shipped was $ 411.80 thanks to the over the top shipping costs..

Read about the soldering, I just didnt want to pull them all apart and find it was a failing microswitch . so figured I'd put something 12 years newer in

Wasn't aware if ccm handshake issues. Not mentioned on ecs. Mines an 02 as well, so not sure on the split anyway.

Just hope my window clips don't break