MrP's GTI - Weekend of fail...

[MrP]

Been a long long time since I have updated, been a busy boy though...

First up... More pictures of the photoshoot a few posts up...

[alexperkins]

looking good pro

especially liking the tidy mk3 GT

[MrP]

I decided to give the GTi a bit attention it deserves...

First up decided to change the xenon bulbs for some Osram Cool Blue D2S ones. They are 5000k compared to the Osram 4200k supplied by VW as standard. Should be just as bright but give a bit of a blue tint to make them look a little more modern. Also fitted some matching White LED sidelight and some Osram night breaker full beam bulbs.. I have some LED fog and number plate bulbs on order but the seller is messing me about.. Don't have a photo of them fitted as yet.. But here are the parts...



Also decided to give it a full service and some love.. Genuine VW Parts only... Forgot to include Oil in the picture, but used Castrol Magnetec 10w40, it's been used it's entire life!

Managed to get my grubby mittens on my stepdads DSLR... Shhh, don't tell him!



Genuine VW Clutch cable.. It was the original at 113k and was causing some sudden jumping of the clutch when first used in the morning so was probably sticking.. You can see the difference in the pic!



Mmmmm.. Fresh!



Pollen filter, original was a VW one (as is the replacement) so guessing a good few years old looking at the state of it! Surprisingly no more steamy windows after I fitted this..



Replacement HT's for Genuine VW items, one of the originals was split and electrical taped to stop it arcing..



New VW spark plugs, exactly the same as the ones fitted by the previous owner who used GSF items, just twice as expensive, I think the VW symbol gives 10bhp



Also fitted a replacement coil, all the 6n2 (petrol engine) coils are the same. My original had corroded contacts and was also missing one contact!!! My new one had mint contacts.. It's hard to see in the picture, but the contacts are mint, trust! Don't have a picture of the old one as it went straight in the bin!



New fuel filter, Judging by the service history I think the original has never been changed!! Made a school buy error and removed the old one without checking the flow direction! (It goes towards the passenger side by the way )



Fitted a new rear microswitch and boot mech due to my boot light not working.. Only wanted a microswitch but the VW guy had one of these in stock so gave me the full unit at the same price as the switch

Turned out the switch had corroded




Also fitted a new throttle cable, I know these cars use EPC (drive by wire) but they have a little cable above the pedal and a metal fixing which twists the potentiometer (the device which reads the throttle position) this part becomes slack and twists causing a low pedal (as I described a few posts above). A low pedal obviously means you can't get full throttle, according to VAGCOM mine was getting 78% throttle at the lowest pedal point!!!

Absolute pain in the F*****G A**E to fit, had to remove the drives seat, all of the dash undertrays to just get enough space for one hand to reach it.. I will do a proper DIY guide to solve the issue soon.. This is the part needed:



It's one of the parts linked to number 22 at the bottom of the picture.. In short, the hole on the above part is pushed onto to a splined shaft on the throttle potentiometer (the cylinder thing in the below picture, also part of 22) using a bolt. When the pedal is pressed, the cable is pulled thus twisting the metal section and of course the potentiometer. This metal part and cable eventually twists and wears causing a lower than normal pedal position. You can't see on the above picture, but the used item has a spline in the hole and the new item doesn't. The spline is created when you tighten the bolt up, which shows how soft the metal is so it's obvious why it eventually twists.



Basically you have to lie on you back and put your hand through where I have circled whilst looking at it all from underneath.. Holding the original cable tight from underneath whilst undoing the bolt from the circled hole. The bolt is not very tight so is relativity easy as long as you have girly small hands, which I don't. When both your hands are in place you can't see a thing so Jedi powers are a must here.



A zoom in of the position of the part to be replaced.. You can see how far back it is..



I removed the entire pedal for ease of fitting.. It's actually essential to remove this if you want to use your hand from underneath. Refitting is basically reverse of removal, although you have to hold the pedal in the position you want it to stay, but do this without actually fastening the pedal in place.. 3 hands are preferred here, or use your head/teeth to hold the pedal like I did.



As said earlier I changed the oil for Magnetec and I also fitted a ECS magnetic sump plug, I will update whether this works or not in 6,000 miles!



Car in pieces!!



Also fitted the front car mates, Official GTi ones.. Rears are on back order and should be arriving soon.



Overall, the car drives much much nicer now!! It's a lot quieter and rev's much more freely! Yay!

[alexperkins]

Very nice What measurement block did you use to determine the throttle opening percentage dude? Might have a look at mine to check its working properly

Also, did you check it afterwards to see if the value had changed?

Im gonna try and get me a set of the red mats, but as far as im aware, they are now discontinued as of the 23rd of August this year

[MrP]

Very nice What measurement block did you use to determine the throttle opening percentage dude? Might have a look at mine to check its working properly

Also, did you check it afterwards to see if the value had changed?

Im gonna try and get me a set of the red mats, but as far as im aware, they are now discontinued as of the 23rd of August this year

Well, my front mats came a few weeks ago, the rear mats came, but were the wrong ones (no red stripe) which may explain why.. Although, they were ordered before the 23rd.. I could kick up a fuss and see what happens.

As for the throttle cable, I now get 100%, but at about 3/4 of pedal push, any more it stays on 100%. In all honesty it felt like driving a new car afterwards.

Can't remember the measuring block, I will check tomorrow.

[pocketrocket786]

Would you be willing/able to provide part numbers for the bits you got replaced matey? (HT Leads, Fuel Filter etc)

[MrP]

Would you be willing/able to provide part numbers for the bits you got replaced matey? (HT Leads, Fuel Filter etc)

Of course dude,

I'll dig out the receipts tomorrow, I'll include retail prices too...!

[MrP]

Also fitted a new clutch kit a few months ago, only just dug out the photo's

Went for the Sachs kit due to so many recommendations + it was half the price of the VW Vaelo one.

The original one went at 112,000 believe it or not, still had lif on the plate skin too!

New Vs Old, as you can see, loads of life left, just one of the springs had snapped, not bad going for 112k!



Clutch fitted:




Release bearing fitted:



Also changed a few O-rings whilst I was at it...




The clutch was much much lighter and well worth the effort!

[MrP]

Not long after fitting the clutch I was getting the emissions light on the dash, VAGCOM pointed to the pre-cat lambda. It was misfiring badly and runnign like crap. After changing the coil, HT leads, spark plugs still no joy.

Turned out to be a split wire on the engine loom side leading towards the pre-cat lambda..

I tried to solder the split wires but they had snapped too close to the plug



Managed to get hold of a spare section of loom from a good mate:



Soldered it all up good and proper and it's still fine a good 1000+ miles later!

[MrP]

Last on my update is changing the gearbox oil. This was last done 18 months ago and 14,000 miles...

Just look how dirty it was after such a short time:




Especially compared to the new stuff from VW... Lifetime oil apparently. My arse!



Expect another DIY guide on gearbox oil changes!!

[Dom_]

Good stuff! Will feel like a new car after all that

I've wanted to fix my lazy pedal, but after reading what it's like to do...don't think i'll bother

I really want them floor mats too, but now they've been discontinued it'll be a right pain...there's a set on ebay but the person wants £100 for 'em, must be bloomin' mad!

[MrP]

Good stuff! Will feel like a new car after all that

I've wanted to fix my lazy pedal, but after reading what it's like to do...don't think i'll bother

I really want them floor mats too, but now they've been discontinued it'll be a right pain...there's a set on ebay but the person wants £100 for 'em, must be bloomin' mad!

£100 for some used mats!!? Can get tailored for that price I reckon.

The pedal is well worth the effort, trust me. My car felt like a different machine afterwards. Do it!!

[Dom_]

Well they were brand new and still in the bag! But £100 is still a lot of money for a bit of carpet

Are you doing to do a guide on the pedal too, that'd be awesome As I'd imagine most peoples pedals are like that

Also, was your old clutch cable really notchy/gritty at times? Making for awkward pulling away at times?

[MrP]

Well they were brand new and still in the bag! But £100 is still a lot of money for a bit of carpet

Are you doing to do a guide on the pedal too, that'd be awesome As I'd imagine most peoples pedals are like that

Also, was your old clutch cable really notchy/gritty at times? Making for awkward pulling away at times?

I will do a comprehensive guide on the pedal box yeah..! Watch this space..

I bet he bought em up to flog on.. I hate people who do that..

Yes, the clutch cable was stiff, grinding and notchy (even after a new clutch). When driving the car after it had been sat for a while, usually over night it would kinda jerk on the pull away, kind of like lifting the clutch up quickly, but without moving my foot from the clutch pedal.

[Dom_]

Yeah that's what mine does! According to my history the cable is only as old as the clutch itself (12k), so whether it's a cheap pattern cable that's just gone bad

Did you get your bits from a VW dealer or TPS?