"Wolfie" Golf Mk4 1,6L AKL 5sp manual DUU - Build :)

[YellowLemon]

Hello mk4 land! I recently acquired a 2001 Golf Mk4 in Reflex Silver. It's the POVSPEC 1,6L petrol, engine code AKL, with everyone's favourite 5sp manual gearbox code DUU. For your interest here are some of the mainly aesthetic & comfort mods I will be undertaking:

01 Pioneer AVIC F-960DAB Digital Radio Navigation



02 Polaris Heads-Up Display



03 Illuminated italian leather shifter boot, made in Germany



04 ESUSE custom DRL for mk4, made in Taiwan



05 R-dash number plate lights (from Polo 6R)

[YellowLemon]

06 Hella 'Magic Color' Smoked black taillight clusters
.

07 W8 dome light with illuminated switches and ambient LED light
Needs a wire taken up the A-pillar carrying "Klemme 58d" dimmed illumination power


08 Rear View Camera installed above numberplate
I could install this easily without removing the bumper. Just take out the plate bulbs and manoeuvre the wiring with fingers/tools/cable snake.


09 OEM short FM antenna from Polo 6R

[YellowLemon]

10 Remote central locking kit installed under dash, wired into driver door.
Got the unit for less than twenty bucks on eBay. The local locksmith cut the blades $40 each, and then had to get ID48 transponders from KeyMam for about $10, plus the old VagTacho off eBay, as described in the great sticky on this forum.



11 LED footwell lights
They are wired up to the dome light: they turn on when you unlock the car, open the doors, or use the dome switch. Very 'stock' like



12 Sony wired remote control RM-X4S.
An alternative idea is to fit a Mk6 GTI wheel with the DSG paddles, and develop an Arduino board to interface between the MFSW LIN bus and the Pioneer. The Arduino would take over the horn wires in the slip-ring on the wheel side, and then provide a horn output on the car side (in Mk5/6 the horn runs over LIN bus). Also the arduino would have to convert the 58d dimmed lighting input signal to a LIN bus command to turn on the MFSW illuminated buttons



13 New OEM boot struts so the hatch doesn't hit my head
Cost less than forty dollars posted from overseas. No idea if a 'regas' would have been cheaper - but definitely more effort I presume.



14 New fuel filler cap solenoid
The old one died on the "door always open" position. I look forward to pulling all of the boot trim apart to accessing the damn thing.

[YellowLemon]

Oh, and lucky last for now:
15 FIAMM® Freeway Blaster Horn
The stock horn's meek 'meep meep' sounds like the road runner, or maybe a scooter. And this is Melbourne after all, so we need a good horn.



Other stuff:

Soft touch plastic
- I gutted the interior off all the plastics which were plagued by the dreaded "soft touch" deterioration, it was all sticky-icky and peeling with hairs stuck to it etc. etc. The trick to fix it was using 100% isopropanol (or 100% ethanol works great too, if you can come by it ) to actually dissolve the soft touch stuff, to reveal nice black plastic underneath. No need for scourers or anything, just a whole lot of cotton cloths. The black gum will actually end up on the rags, I used about 10 rags to get rid off it all, took about 3 hours.

Gear lever became 'sticky' when car warm, and won't return to neutral position
- When the car was warm, the side-to-side movement of the gear lever would become difficult to move, and the lever wouldn't return to the neutral position. This made it hard to tell which gear I was shifting into. The car had just had the transmission shift linkages completely renewed. The problem was solved by spraying silicone lubricant and white lithium grease onto the shift linkage pivot points (under the hood near the transmission) and now it shifts super smoothly. Interestingly most of the info I found online (US based) related to a dual cable-based manual shifter, however the 1,6L manual has an old single rod-style system similar to Mk3 and Mk2 (I believe), this is what it looks like all greased up:



DUU transmission
The car needs a new clutch soon. Would it make sense to install the stainless steel bolt kit into the transmission at the same time?? Or just wait until it fails & cracks and fix it then.... It's been fine now for 170'000km, so maybe it's not affected by the shearing rivets on the final drive gear? Any advice appreciated

Thanks for reading.

[Feeine]

The Polaris HUD seems really cool! nice to see another person modding a non gti mk4

[JustCruisn]

Wow nice shopping list.

Can you give some detail about those gas struts for the hatch ? I got decked last week, knocked me to the ground, had a headache all day.

If your horn sounds like road runner, then the bass horn is probably gone, there are two

[YellowLemon]

Hi JC the hatch struts part number is 1J6827550C (for both sides, and also the same for the single one that holds the bonnet up) I ordered a pair from this link:

VW Passat B5 5 Wagon Bora Golf MK4 Tailgate Damper Shock Strut Prop X2 Pair | eBay

Another seller had them in stock locally in Melbourne but at twice the price.

Do you know where the second (low) horn is? Mine has a single horn just behind the front foglight vent on the L side of the car.

[dylan8]

Can you put the w8 in a non sunroof car?

[YellowLemon]

Hi Dylan there seems to be a sunroof and non-sunroof version of the so-called W8 dome light: The non-sunroof version is the same size as the standard mk4 dome light. In some cases, some foam in under the roof liner needs to be pushed aside or cut away, because the W8 light plug comes out at 90' degrees to the side, whereas my stock one the plug comes out straight 'up'.

The light I got included the adapter for stock <-> W8 connectors (ebay germany I think it was) - so no soldering required. But to run the illuminated buttons and ambient LED, it needs to be wired down to the dash.

[YellowLemon]

Daytime driving lights installed:







They are plenty bright

[YellowLemon]

Pioneer AVIC double DIN unit installed:
Needed lots of wiring (reverse, speed sense, separate DAB antenna stuck to the window...)



Dynamat on the outside door skins:
I was too lazy to do it properly on the inside of the doors. Taking the skins off allegedly requires removing or taping the windows glass, etc etc. I'll do it when the window clips break and I have to replace them


Picture of the center console removed to help clean the soft-touch stuff off, and to run wiring for the illuminated gear knob still to come:



I also cleaned out the insides of the instrument cluster. Turns out it's a crappy Bosch "MotoMeter" RB8 unit, not made by VDO, so that's gonna be fun trying to get the PIN/SKC code from using VAGTacho... NOT!

[dylan8]

Ahhh didn't know there was a non sunroof one, cool

[Jmac]

You can still get the SKC , but you will need the car hooked up to a decent charger as it can take at least an hr to seed the key. They can be a pain but still doable. Oh and yes the clutch is 80-90% worn, your not wrong there
Jmac

[aaron001au]

Good to see another 1.6 getting done up

[YellowLemon]

Photoshoot

Photoshoot after 'paint correction' using an orbital polisher and Scholl S3 & S17: