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Thread: Bora R32 Build Thread

  1. #111
    Join Date
    Apr 2014
    Location
    Penrith, NSW
    Posts
    646
    Users Country Flag Thread Starter

    Haven't updated this thread in a while, so here goes.

    April 2021 - Lost clutch pedal. Found the seals on the bleeder block had blown out. The MKIV seals have been revised and now share the same style seal as the MK5's.

    Old style seals that sit inside the bleeder block
    Bora R32 Build Thread-172243622_3730286283749067_307519258958888911_n-png

    New style seal (slides over the clutch line)
    Bora R32 Build Thread-171048793_888026918687535_2891380882257192255_n-png

    Also got sick of the BC coilovers that were just eating tyres (too much neg camber)

    On BC's
    Bora R32 Build Thread-img_3883-jpg

    Bora R32 Build Thread-img_3884-jpg

    Threw the stock springs just to get a base line height (approx 37mm)
    Bora R32 Build Thread-img_4249-jpg

    Then finally decided to put the R32 stock suspension in. Can confirm R32 v Stock Bora suspension gave me a drop of about 10-15mm all round. Firmed up the suspension nicely also. You can see the height difference in the rear springs.

    Bora R32 Build Thread-img_3898-jpg

    Bora R32 Build Thread-img_4250-jpg

    Bora R32 Build Thread-img_4253-jpg

    Bora R32 Build Thread-img_3902-jpg

    Final ride height (approx 35.5mm)
    Bora R32 Build Thread-img_4488-jpg
    Last edited by beale187; 27-07-2021 at 02:08 PM. Reason: Picture
    2004 VW Bora V5 | Daily (Until the Bora R32 rises from the ashes!!)
    2004 VW Bora 4motion Oettinger | DBA Slotted Rotors | R32 Trim | 3 BBE Exhaust
    2004 VW Golf R32 | Donor / Part Out

  2. #112
    Join Date
    Apr 2014
    Location
    Penrith, NSW
    Posts
    646
    Users Country Flag Thread Starter
    June.

    Driving to work, get this message "STOP OIL PRESS" warning, was intermittent over a few days.

    So that weekend decided to drop the sump to see what's going on.

    Find a piece of the plastic baffling floating around in the sump, I can only assume it was occasionally getting caught in the oil pickup.

    Was pretty happy though, oil was clean with minimal sludge. Cleaned up the sump, checked the oil pick up and went back to business. Curious, found a QR code on the bottom of the block?

    Bora R32 Build Thread-img_4278-jpg
    Bora R32 Build Thread-img_e4282-jpg
    Bora R32 Build Thread-img_e4283-jpg
    Bora R32 Build Thread-img_4279-jpg
    Bora R32 Build Thread-img_4280-jpg

  3. #113
    Join Date
    Apr 2014
    Location
    Penrith, NSW
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    July.

    This motherf@&^er. More coolant leaks.
    Bora R32 Build Thread-img_4396-jpg

    Decided to pull everything apart (again, 5mths after the changing the last radiator) only to find the radiator was leaking in the exact spot as last time.

    Bora R32 Build Thread-img_4411-jpg

    Surely couldn't be a coincidence? Nope, turns out this whole time it was the fan assembly. It's either from an 4cyc (VR fans are slimline) OR I suspect it's an aftermarket Topran assembly. Anytime there was some "spirited driving" or heavy braking, the fan assembly was slowly punching the radiator.

    The center of the Topran fan assembly sat much prouder in the shroud then the OEM - Not too mention the sharp bolt ends.

    Topran
    Bora R32 Build Thread-img_4418-jpg

    OEM 2.8 Bora
    Bora R32 Build Thread-img_4419-jpg

    Almost forgot the mention, look like the whole shroud was bowed in the middle.
    Bora R32 Build Thread-img_4445-jpg

    Replaced everything, finger crossed that's the end of the coolant saga.
    Attached Thumbnails Attached Thumbnails Bora R32 Build Thread-img_4412-jpg  

  4. #114
    Join Date
    Oct 2007
    Location
    Bairnsdale & Ferntree Gully, Victoria
    Posts
    7,464
    Interested in what's your findings on the vr6 fans being thinner? Is that to allow for a big radiator or more space at the rear?

    Sent from my HTC 2PZC100 using Tapatalk

  5. #115
    Join Date
    Apr 2014
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    Penrith, NSW
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    Quote Originally Posted by dylan8 View Post
    Interested in what's your findings on the vr6 fans being thinner? Is that to allow for a big radiator or more space at the rear?

    Sent from my HTC 2PZC100 using Tapatalk
    V5/V6/R32 all run a 34mm core radiator, so the fans are slimmer
    4cyc's run a 26mm core radiator.

    They all have the same mounting points so physically they're all interchangeable but as above you gotta run the slimmer fans on the VR's to avoid the problem I had. You could probably run a 26mm radiator if you had one and got stuck but I wouldn't run it long term. VR's run hot baby

  6. #116
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    Oct 2007
    Location
    Bairnsdale & Ferntree Gully, Victoria
    Posts
    7,464
    Interesting. Might save me importing some stuff for the wagoon

  7. #117
    Join Date
    Apr 2014
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    Penrith, NSW
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    So for a while now I've had this annoying whistling noise and a hunting idle so I knew I had a vac leak somewhere.

    Tracked it down to the PCV diaphragm, which is common issue on the MK5 3.2's. Whistling noise was coming from here.
    Bora R32 Build Thread-pcv-venthole-jpg

    Worse bit, some F&^%ing moron at VW decided to put it inside the valve cover. So to replace it was a bitch.

    Figured whilst I had the manifold and valve cover off I'd replace all the seals and give the valve cover and manifold a lick of paint. Also ordered some R36 blue coil pack covers to suit.

    Parts ready to go. Replacement PCV diaphragm from RKX Tech in the US. Hard to Find Parts and Accessories for Volkswagen and Audi Vehicles – RKXtech
    Also ordered a 5mm block off cap from OCDEURO Australia | VAG Auto Parts | Internal Chassis Bracing to put on the back of the manifold where the charcoal canister was deleted by the previous owner.
    Bora R32 Build Thread-img_4668-jpg

    Manifold & valve cover painted
    Bora R32 Build Thread-img_4578-jpg

    Previous owner blocked the port on the back of the manifold where the charcoal canister would normally go by cutting the tube and sticking an old allen key in there. Remember, it's not stupid if it works.
    Bora R32 Build Thread-untitled-jpg

    Block off cap installed
    Bora R32 Build Thread-245073136_604595477251273_5735376170652207860_n-jpg

    manifold off
    Bora R32 Build Thread-img_4680-jpg

    Good time to clean out carbon build up on the intake port. 1 down, 5 to go.
    Bora R32 Build Thread-img_4681-jpg

    Valve cover off
    Bora R32 Build Thread-img_4684-jpg

    Quick inspection of the Schrick 268/264 cams. I'm assuming this is the batch number.
    Bora R32 Build Thread-img_4687-jpg

    Bora R32 Build Thread-img_4688-jpg


    Old PCV diaphragm, thing had holes in it all over the place.
    Bora R32 Build Thread-img_4695-jpg

    New RKX one installed, pulled the oil separator apart and gave it a thorough clean.
    Bora R32 Build Thread-img_4672-jpg

    Threw everything back together. Included torque specs below for future reference.

    Bora R32 Build Thread-capture_torques-jpg

    ALSO note, for anyone reading this with the same problem. There is an easier solution (which I was not aware of until after completing this bullsh*t job) The VW Touareg 3.2 has a similar PCV setup but the diaphragm is located EXTERNAL of the valve cover. Link below with a detailed write up of how it works, parts needed and how to repair it without going through the process I did above.

    3.2 VR-6 (BUB) PCV Diaphragm Replacement Alternative | Audi TT Forum
    Last edited by beale187; 12-10-2021 at 10:42 AM. Reason: additional

  8. #118
    Join Date
    Apr 2014
    Location
    Penrith, NSW
    Posts
    646
    Users Country Flag Thread Starter

    Another thing that was really bugging me was the 2.8 harness runs along the top of the manifold but the 3.2 runs along the bottom.

    So I started stripping off all the split tubing and begun wrapping the harness in TESA tape. Unfortunately I hit 2 snags.

    First being that 3 wires were not longer enough to route along the bottom. Second being the coil packs on 2,4,6 would not seat properly when rotated 180' degrees. After speaking with another legend on here he advised some of the coil packs were different lengths. Yet to confirm this but I suspect that may be the issue. Anyway tidied it up best i could and left it for another day.

    split tubing just fell apart
    Bora R32 Build Thread-img_4762-jpg

    Attempt to reroute wiring
    Bora R32 Build Thread-img_4763-jpg

    Before
    Bora R32 Build Thread-img_4673-jpg

    After
    Bora R32 Build Thread-img_4764-jpg
    2004 VW Bora V5 | Daily (Until the Bora R32 rises from the ashes!!)
    2004 VW Bora 4motion Oettinger | DBA Slotted Rotors | R32 Trim | 3 BBE Exhaust
    2004 VW Golf R32 | Donor / Part Out

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