Polo restoration project #2 - 2017 GTI Manual

[Sharkie]

Late 2022, I came across a bit of a unicorn ... a manual 2017 GTI that needed attention after a light front-end mishap. Could not resist and another restoration project kicked off.

An altercation with a trayback ute did not end well for the little GTI.



Rare manual

Super low milage, meant I could not pass on it.

[Sharkie]

The little Polo sat around for a few months till after Xmas and some overseas breaks, so only got to start stripping in Feb 2022.

It was obvious the accident was entirely the previous owner's fault as the front tyres were very much not legal/road worthy ....

Initial damage assessment that it was mainly front bits only (lights, bumper, grilles, radiator, condensor, fans and cradle) with 1 (LH) fender and the bonnet and no structural damage. Seemed easy enough



"No structural damage" luckily was correct, however ....

the angle of the impact, did manage to destroy the waterpump, crack the intake manifold, crack the throttle body and crack some boost pipes. Pity you cannot inspect cars prior to purchase from Pickles these days.


So, fitted a new intake manifold (cleaned the intake ports which was full of carbon build-up at only 48K kms and that is with direct and port injection), fitted a new waterpump and a new throttle body. Also fitted the boost pipes from my Golf R which got a DO88 pipe
upgrade at the same time).

[Sharkie]

Since a new cradle was going in anyway, upgraded the intercooler at the same time. Massive difference

[Sharkie]

In typical VW OEM fashion, the front brakes were "illegal/definitely not roadworthy" at less than 50,000km ...

This past weekend, replaced the front brakes with DBA XS4000 discs (slotted and drilled) and RDA Phantom ceramic pads.




And with that done, the GTI is fully mobile with only cosmetics to finish up (fit replacement bonnet and bumper)

Test fitted an aftermarket R style front bumper ... and I like it a lot, now just need get it painted (the only part that needs painting on the whole build!)

[guile]

Nice work mate, looks like it’s coming along well…

[MIG]

Great work!

Auction sites can be tempting

[Sharkie]

Thanks guys, happy with the work we've done so far, the killer in these projects on a VW is the parts ... to get a good price on a new part, you need to reach out to the corners of the earth ... literally.

new waterpump from Lithuania was under $600 shipped, waited 3 weeks for it vs ~$950 from VW and a 1 week wait
new set of fans for the radiator from the USA was $200 shipped, waited 6 weeks vs $1100 from VW and a 4 day wait
new inlet manifold (incl injectors and fuel rail) from the UK was $800 shipped, waited 3 weeks vs $1400 from VW and a 2 week wait

Saving money on the build often then comes with quite lengthy delays ... especially if you only discover you need a new manifold AFTER you finished installing the water pump . Compounded delays really LOL

Some parts such as body parts can be had quite cheaply if you use the wreckers, especially if you can get them in the same colour ...

[Sharkie]

Auction sites can be tempting

My wife keeps trying to convince Pickles to ban me .... I'm always looking, might have an addiction. Luckily I only have so much space available to store and work on projects so am forced to resist the temptation.

[Sharkie]

Some progress this weekend, it's getting pretty close to being fully done now.

Bumper back from paint, parking sensor holes drilled (before paint) and parking sensors fitted



Replacement bonnet fitted



Left to do is finishing off the bumper (post paint polish), installing the grilles and hooking up the sensor loom.

[Sharkie]

RWC done , and ready for final inspection and registration.


Last step is to fit the painted black grille badge.

[Lucas_R]

Congrats on a job well done. Must be a happy moment to have an inspection signed off after doing a repair like this.

[Sharkie]

The project has now completed the "back on the road" phase.

Registered and useable so user acceptance testing commenced


UAT resulted in ...
1. Driving it more than just a few hundred meters at a time did reveal a small coolant leak which came out of a 5mm cut in what I call the water pipe spaghetti between the waterpump and the radiator. Temporarily patched it, ordered a new OEM pipe from VW and fitted last weekend. Had to buy the whole piece of spaghetti at mucho $$$


2. Foglight error as a result of the R style front bumper without foglights. Fixed with VCDS coding with Don's (DV52) help!

[Sharkie]

Mod Phase has now commenced .... watch this space

To be fair upgrading the brakes and the FMIC in the previous phase unfortunately meant it was never going to stay stock

[Sharkie]

We keep on learning about the nuances in the differences with the 1.8TSI in the Polo and what is in the 2.0TSI engines in the Golfs etc. You need a specific Turbo Inlet as the PCV feed connection sits on the opposite side of the bend compared to the 2.0TSIs.

Even though every site will sell you a TIP advertised as suitable for an EA888.3 2.0TSI and 1.8TSI .... trust me its not

Ended up finding a RAMAIR TIP that worked, and installed a custom CAI (RAMAIR TIP, CTS elbow and K&N pod filter). Just need to finish the heatshield still, but the sound it makes is amazing.




An IS20 is also sitting on the workbench begging me to be installed LOL

[doc_777]

My son has the full ramair intake on his 6C - sounds brilliant.