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Thread: Bora R32 Build Thread

  1. #71
    Join Date
    Apr 2014
    Location
    Penrith, NSW
    Posts
    600
    Users Country Flag Thread Starter

    Pulled the dash out of the R32 (identical to the Bora dash, same part no.)
    Bora R32 Build Thread-img_9456-jpg

    Bora R32 Build Thread-img_9457-jpg

    Bora dash, note huge crack from airbag.
    Bora R32 Build Thread-img_9545-jpg

    R32 dash, schmick!
    Bora R32 Build Thread-img_9546-jpg

    Epic job.

  2. #72
    Join Date
    Jul 2008
    Location
    Braidwood, rural NSW
    Posts
    3,046
    Users Country Flag
    Thanks for sharing but glad it was you doing all this not me.

  3. #73
    Join Date
    Apr 2014
    Location
    Penrith, NSW
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    600
    Users Country Flag Thread Starter
    Here's how it sits now. Everything replaced, wired up and good to go!

    Bora R32 Build Thread-img_9634-jpg

    Bora R32 Build Thread-img_9625-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

  4. #74
    Join Date
    Mar 2017
    Location
    Sydney
    Posts
    107
    wow, good as new, looks clean, nice!
    2002 Golf GTI - K03S | 3" Downpipe | 312mm DBA T3 Slotted with Forza Pads | | Forge 008 | Forge Hoses | ECS Performance Mounts | R32 and Urethane Bushings | Pipercross Filter | Sachs VR6 Clutch with 14lb Balanced Flywheel

  5. #75
    Join Date
    Apr 2014
    Location
    Penrith, NSW
    Posts
    600
    Users Country Flag Thread Starter
    Well here we go again....
    After a few weekend's on the tools and a brief game of "musical MK4's" the R32 engine is finally out!

    Bora R32 Build Thread-img_0052-jpg

    Bora R32 Build Thread-img_0053-jpg

    Bora R32 Build Thread-img_0055-jpg

    All the steps involved mentioned in prior pages for removing the BDE engine were identical for the R32. With the exception of these 2 items.

    Vaccuum Line for Exhaust Flapper
    Bora R32 Build Thread-img_9950-jpg

    AND, the Secondary Radiator
    Bora R32 Build Thread-img_9902-jpg

    Undecided what to do with both at the moment but that's a problem for another day.

    Whilst the R32 engine is out I'll be doing chains/guide and clutch. So I'll start stripping the engine down over the next couple of weeks.
    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

  6. #76
    Join Date
    May 2015
    Location
    Melbourne
    Posts
    211
    Users Country Flag
    Moving on nicely with things there Mr B!

  7. #77
    Join Date
    Apr 2014
    Location
    Penrith, NSW
    Posts
    600
    Users Country Flag Thread Starter
    Engine is getting stripped down, ready for clutch, chains and guides.

    Bora R32 Build Thread-img_0243-jpg

    Definitely in need of a new clutch! This was it at about 150,000kms.
    Bora R32 Build Thread-img_0244-jpg

    Whilst I wait for those bits to arrive thought I'd turn my attention to something that was bugging me. Apparently the previous owner or their mechanic had no idea how VAG electrical connectors work . 4/6 coil plug were completely destroyed along with one injector plug. So it was swap them out

    Bora R32 Build Thread-img_0264-jpg

    So I grabbed the loom from the BDE Engine armed with my eBay tools and got to work.
    Bora R32 Build Thread-img_0276-jpg

    Replacing Coil connector (P/N 1J0973724)

    Slide the purple retainer to the side
    Bora R32 Build Thread-img_0266-jpg

    Remove the connector cover
    Bora R32 Build Thread-img_0265-jpg

    Insert ebay Tool (3mm) into top and bottom and push down till it clicks.
    Bora R32 Build Thread-img_0267-jpg

    Pull out terminal wire from the back.
    Bora R32 Build Thread-img_0268-jpg

    Repeat x4.. LH R32 connector (the terminal block actually snapped off this connector. Not sure if it was just brittle or I wiggled the terminal tool and snapped it meh..), RH Bora BDE V6 connector. Same p/n though. Installation in reverse.
    Bora R32 Build Thread-img_0269-jpg

    Next time to replace the injector plug (P/N 06A973722)

    Lift the purple retainer up and out.
    Bora R32 Build Thread-img_0270-jpg

    This one was a little tricky to get a pic of but there is a small black clip on the inside which needs to be pryed up.
    Bora R32 Build Thread-img_0275-jpg

    Then just pull it out from the back. Installation in reverse.
    Bora R32 Build Thread-img_0271-jpg
    Attached Thumbnails Attached Thumbnails Bora R32 Build Thread-img_0275-jpg  

  8. #78
    Join Date
    Apr 2014
    Location
    Penrith, NSW
    Posts
    600
    Users Country Flag Thread Starter
    * REMOVING THE SUBFRAME, SUSPENSION, P/S RACK, SWAY BAR - R32*

    Back to it over the weekend.

    First step, disconnect the steering column from the rack.

    Remove the deadpedal
    Bora R32 Build Thread-img_0487-jpg

    Unbolt 13mm bolt from steering column universal joint
    Bora R32 Build Thread-img_0488-jpg

    Remove headlight level sensor from chassis
    Bora R32 Build Thread-img_0489-jpg

    Bora R32 Build Thread-img_0490-jpg

    Now onto the Brakes, these are eventually going on the Bora.

    Disconnect brake pad wear sensor

    Bora R32 Build Thread-img_0491-jpg

    disconnect ABS sensor
    Bora R32 Build Thread-img_0493-jpg

    Pull away ABS sensor wiring away from strut.
    Bora R32 Build Thread-img_0495-jpg

    Bora R32 Build Thread-img_0496-jpg

    Remove brake line plastic shield and line clamp and remove from strut. Remove 2x 19mm brake carrier bolts and wire tie brake assembly to body of the vehicle.

    Bora R32 Build Thread-img_0494-jpg

    Bora R32 Build Thread-img_0497-jpg

    Undo 2x 21mm strut nuts (impact required or strut socket)

    Bora R32 Build Thread-img_0498-jpg

    Not necessary but as I was doing it solo i used some elastic straps to tie up the struts so they wouldn't just fall forward when lowering the subframe.

    Bora R32 Build Thread-img_0499-jpg

    Undo 4x subframe bolts (24mm from memory and they are TTY, replace with new according to VW)
    Bora R32 Build Thread-img_0501-jpg

    Bora R32 Build Thread-img_0502-jpg

    Lastly, 2x 13mm O2 sensor wiring shield at the rear of the subframe
    Bora R32 Build Thread-img_0506-jpg

    Then all that's left is to lower that bad boy down.

    Bora R32 Build Thread-img_0500-jpg

    Bora R32 Build Thread-img_0510-jpg

    DONE! I'll give it a clean up then bolt it up to the Bora.
    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

  9. #79
    Join Date
    May 2015
    Location
    Melbourne
    Posts
    211
    Users Country Flag
    woop woop - nice progress!

  10. #80
    Join Date
    Apr 2014
    Location
    Penrith, NSW
    Posts
    600
    Users Country Flag Thread Starter

    Pulled the .:R subframe out on the weekend gave it a quick clean up before the install and got it all fitted up. Will need to replace the bolts at some stage as they're one-time use and get torque'd to 100nm +90

    Bora R32 Build Thread-img_0649-jpg


    Struts to body were 60nM
    Bora R32 Build Thread-img_0671-jpg

    Also got around to fitting the front brakes as part of that, they'll need new fluid but that's a little hard to do with being able to cycle the ABS pump. Found that I had to swap out the front brake lines to match the R32 calipers, they were slightly different between the 4motion and R32. Lastly carriers to hub were 125nM (little loctite if they look worse for wear).

    Bora R32 Build Thread-img_0653-jpg

    different in 4motion (right) brake lines V R32 (left)
    Bora R32 Build Thread-img_0655-jpg

    Bora R32 Build Thread-img_0672-jpg

    Bora R32 Build Thread-img_0673-jpg

    Next up, rear shocks and springs!
    Last edited by beale187; 14-10-2019 at 12:45 PM.
    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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