"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
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02 Polaris Heads-Up Display
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03 Illuminated italian leather shifter boot, made in Germany
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04 ESUSE custom DRL for mk4, made in Taiwan
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05 R-dash number plate lights (from Polo 6R)
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[YellowLemon]

06 Hella 'Magic Color' Smoked black taillight clusters
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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
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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.
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09 OEM short FM antenna from Polo 6R
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[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.
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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 :)
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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 :)
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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.
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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.
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[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.

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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:

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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 :D

Thanks for reading.

[Feeine]

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

[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 (http://www.ebay.com.au/itm/VW-Passat-B5-5-Wagon-Bora-Golf-Mk4-Tailgate-damper-shock-STRUT-PROP-x2-PAIR-/150835540387?pt=Motors_Car_Truck_Parts_Accessories&hash=item231e7fb1a3&_uhb=1)

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.

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[YellowLemon]

Daytime driving lights installed:

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They are plenty bright :cool: :cool: :cool:

[YellowLemon]

Pioneer AVIC double DIN unit installed:
Needed lots of wiring (reverse, speed sense, separate DAB antenna stuck to the window...)
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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 :P
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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:
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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!
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[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 after 'paint correction' using an orbital polisher and Scholl S3 & S17:

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[RolfGolf]

Great job with the polishing - looks really good!

re. horns, lower spec Mk4 were only supplied with the single horn (high pitch - hence the road runner sound), you might have the wiring in place for the dual horn system - it's usually tucked up around where the other horn is and has the same style connector on the end of the wiring.

[YellowLemon]

Thanks! I couldn't find wiring for a second horn - primary plan is to replace the existing horn with an aftermarket "low" and see how it goes.

[RolfGolf]

Thanks! I couldn't find wiring for a second horn - primary plan is to replace the existing horn with an aftermarket "low" and see how it goes.

Anything would be an improvement on the road runner sound. (Dual-tone horns give you that classy European 'parp' sound)

[shauny]

Hey mate, can you put up a link or more details on which central locking kit you went with? I have the exact same model car, and would like to put one in myself. Was it just adding the remote central locking module into wiring loom and get your keys cut on some HAA key blanks that fold up?

[YellowLemon]

Hey mate, can you put up a link or more details on which central locking kit you went with?

Hi mate I got this exact kit here for $19.00 -

Remote Control Central Locking Conversion Keyless Entry KIT FOR VW Golf MK4 MK5 | eBay (http://www.ebay.com.au/itm/Remote-Control-Central-Locking-Conversion-Keyless-Entry-Kit-For-VW-Golf-mk4-mk5-/400660829427?pt=AU_Car_Parts_Accessories&hash=item5d493f14f3)

If you go with the flip keys, you'll need:


Remote kit - $19
HAA blanks cut - $40 each key
2x glass transponder chips VW ID48 from keymam - $15
VagTacho or Vag K Commander clone from ebay - $20


Then follow the "how to program a transponder to your car" sticky in this forum to code the keys to the immobiliser. Alternatively you could try remove the glass immo chips from the existing keys (they may be glued - have a look. It looked too delicate a job for me) and put them in the flip keys, OR glue a transponder chip under the steering column trim onto the immo induction loop, then any key will work.

OR you can avoid the key cutting and immo hassle by just keeping your existing keys and getting this remote kit:

CAR Remote Control Central Lock Locking KIT Keyless Entry System NEW OK | eBay (http://www.ebay.com.au/itm/Car-Remote-Control-Central-Lock-Locking-Kit-Keyless-Entry-System-New-OK-/261535476778?pt=AU_Car_Parts_Accessories&hash=item3ce4baac2a)

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In terms of installation, it is very DIY-able, you only need to connect four wires. First hook up the "N/O" contacts of the central locking kit on to the ground wire (the Golf uses a negative pulse to trigger the lock/unlock)

DIY Instructions:



Remove drivers door panel. It's 5 screws and 6 clips, quite easy
On the window regulator there's a huge plug with like 36 wires going into it. This harness has the 4 wires you need:

Constant Power (+) = Thick red wire
Ground = Thick brown wire
LOCK = Yellow/blue wire on pin 24
UNLOCK = Red/green wire on pin 4 (note pins 4&24 are almost opposite each other, but not quite)

Most installers just mount the black control unit box in the door, it fits easy. Personal preference I ran the lock/unlock wires through the rubber wire boot in the door and under the driver's side dash & mounted the control unit there.

[AALocksmiths]

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!
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I might be a bit far away but if you sent me the cluster I can get the PIN for you.

[YellowLemon]

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.

Thanks heaps for the tips JMAC: getting the SKC took 3 hours using VAG K CAN COMMANDER v1.4, I was starting to worry but it all worked just like you said, thanks!

Details here: http://www.vwwatercooled.com.au/forums/f14/success-how-make-new-key-incl-transponder-61591-post1083245.html#post1083245

[YellowLemon]

Just a quick FYI: The best double DIN surround for the Mk4 in terms of fit and finish matching the OEM panels, this is it:

LINK: 11 101 Radio Fascia 4 VW Volkswagen Passat Bora Golf Install Facia Trim Dash KIT | eBay (http://www.ebay.com.au/itm/281155687898?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649)

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I tried the trim from the Connects2 kit, the official Pioneer double-DIN kit, and several other eBay cheapies, and only this one was any good. Happy motoring :)

[YellowLemon]

I'm still loving this car, I reckon mk4 Golf was the best VW ever made, it all went cheapskate/downhill after that :)

[blackers10]

glad to hear its still going great for you mate!

[YellowLemon]

Car is sold! It was always a joy to drive but just don't have enough time for all these cars :) The audio system sound in this car was fantastic, with the Pioneer Nav headunit and subwoofer under the seat. For those curious, here is a list of parts and expenditure on the car in one year of tinkering:



Pioneer AVIC-F960BT double DIN radio $1499
Michelin PS3 tyres x4 $680
New brake pads + discs x2 $495
HELLA LED tail lights $323
Slimline subwoofer under seat $249
LED DRL (daytime driving lights) $180
Navman driving camera (Dashcam) $149
Polaris HUD heads-up display speedo $129
LED illuminated leather gear shifter $123
Passat W8 dome light from VW Germany $94
Reversing camera $89
New folding keys + transponders $88
Steering-wheel remote control $76
Double DIN brackets and fascia for radio $60
New fuel flap actuator motor $57
Footwell lights $50
New wiper blades $50
Interior LED bulbs $50
New gas struts for boot $44
Fiamm Dual-Tone Horn $42
ASR switch $40
CTEK charging port $40
Paint correction supplies $16
LED Glove box light $14
OEM Polo short rubber roof antenna $10

TOTAL more than $4500