Mk4 Golf GTI Build Thread

This is my 2001 Volkswagen GTI 20V 1.8T 5 Speed Manual.

I bought this car in September 2011 from another Volkswagen enthusiast who had this car tuned for his wife, who really did not need or want anything more than an average car to transport herself to and from work. She really disliked the fact that it was so low, and pushed her husband to sell it and buy her an average sedan and leave it the hell alone. The car came with the following mods:


  • Shaved head
  • Supposedly bored over to 2.0, though some folks disagree and I have not yet inspected the cylinder walls
  • APR diverter valve
  • Eurojet airlines
  • K&N filter & short ram intake / Neuspeed heat shield
  • Remapped ECU to compensate for the said mods
  • FK Silverline coilovers - lowered to 1.25'' in the front
  • 2'' aluminum skid plate
  • Aftermarket stubby
  • MOMO steering wheel
Seller claims the car has 250hp, I do not disagree. I have taken the car to 252KM/h and could have pushed it a bit further.



When I purchased the car, there were no noticeable issues. I was taken on a short ride, just long enough to see what the car could do. Upon further inspection however, there was a bad coolant leak and a noticeable 'clank clank clank' noise that was made on sharp right hand turns. The coolant leak seemed to be coming from the heater hose, so I systematically replaced clamps hoping it would only cost me a few dollars and it would be over with, however, the coolant was actually leaking from the plastic piece (part #17 on VW's diagram of the engine) that connects directly to the engine, and was running down the hose and dripping off which is what initially made me think that's where it was coming from so it ended up costing over $100 for the new piece and $120 in 6L's of spilled Pentofrost SF coolant, but it's done now and that's the main thing. As for the issue on turning, I suspected it to be the left driveshaft. I ordered both left and right driveshafts from Concept-1, went home and got it all prepped and ready to go on. When I removed the left driveshaft, to no surprise the boot was torn and so I figured I was right. I put on the new one and the problem was not solved. I now think it must be the wheel bearing(s) and will now have to bring in into a shop and get that taken care of.


I haven't done any engine tuning, however I have purchased new genuine Monster mats for my car as the fabric just doesn't cut it, especially in the winter. I also swapped my shift knob with a carbon fibre MOMO shifter and will likely get some silver and black pedals to match, right now I have an old set of red/black/yellow MOMO pedals which match the wheel but not the car and are kinda lame. I have also debadged the hatch and eventually want to do a full shave. I'm looking at getting some sawblade rims and spacers as well. I have brand new headlights and an HID kit, as well as a badgeless grill to install but I'm waiting until after the winter to do that.

I am going for a clean look, nothing flashy, no need for speed, that only attracts assholes and cops.

As I progress with my ride, I'll move from a short paragraph to another listing of complete mods the car has. Any suggestions/tips/help is much appreciated. I'm young and inexperienced, though I'm doing the best I can.


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I'll be watching this thread with interest.

Sorry your post got held in the moderation queue as you can only post pictures or links when you have 10 posts and your account has been upgraded (your username will be shown in bold).

We had to do this to stop spammers but it does encourage new members to get involved and a chance to see what a great friendly site this is.
 
When you said you were young I didn't for a moment think you were THAT young. You can barely see over the steering wheel aye? :)
 
nice nick mate

the 250 is probably over as the downpipe and cat are a bad point in the exhaust.
2.0 also seems to be rather much as most seem to be bored out to 1.9 and thats only really nessessary if going over 400bhp it seems.

again the turbo hasnt been changed and a 2001 is more likey to have the smaller turbo on it so at 250 it would most likely be in pieces.
and i dont think the standard injectors are able to cope with that much as well as they are recommended to be changed when hyrbirdising the turbo to get 240bhp (normally seen as the safest limit for the newer turbo )

sorry to have maybe put a bummer on your car but enjoy it
 
Very. Ice, well done... Although can I point out that you don't look old enough to drive in that photo

That's my younger brother, he's 8 and knows bucket loads about different types of cars. It's all he's been taught growing up by his father, my step
father..

nice nick mate

the 250 is probably over as the downpipe and cat are a bad point in the exhaust.
2.0 also seems to be rather much as most seem to be bored out to 1.9 and thats only really nessessary if going over 400bhp it seems.

again the turbo hasnt been changed and a 2001 is more likey to have the smaller turbo on it so at 250 it would most likely be in pieces.
and i dont think the standard injectors are able to cope with that much as well as they are recommended to be changed when hyrbirdising the turbo to get 240bhp (normally seen as the safest limit for the newer turbo )

sorry to have maybe put a bummer on your car but enjoy it

Makes sense to me. I knew some of the mods the seller told me were a bit iffy, but whatever. I am taking it for what it is, doing a few mods of my own and I might get a dyno run to see what the power truly is. I am saving up for a 3'' turbo-back 42 Draft Design exhaust system, seems to be best suited for the 1.8T's. Right now the car is in the garage sitting with a pool of oil on the floor. I bottomed out on some train tracks with a little too much speed so that's coming first, not an expensive fix so I'm glad. During the winter I'll be doing some detailing to make it all shiny for the spring, nothing too flashy though.

When it comes to engine tuning and mods, any help, tips and tricks are beneficial to a newbie like myself.
 
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if you look around im sure one of the passat 1.8t sumps fits with some modification to the pick up pipe. gives you a little more clearance.

ether that or i think it might be APR do shallow sumps
 
I'm liking the progress so far. It's calling out for some BBS rims though...

(I'm also going to move this to the projects section).

I was actually thinking of some sawblade style rims. I would love for some Mercedes Alphards or even vette style blades but to find alphards around here is next to impossible. BBS makes some nice rims I may look into that, thanks for taking the time to look at my thread.

Going to rock these bad boys with some 6000k HID's soon as spring hits.

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if you look around im sure one of the passat 1.8t sumps fits with some modification to the pick up pipe. gives you a little more clearance.

ether that or i think it might be APR do shallow sumps

Yup, the Passat, Beetle and GTI have the same oil pan. I got one without the oil level sensor from Concept-1 for $145 and I have replaced it since I was last on here. Cars running fine again, though my summer tyres don't like the winter roads, it hasn't been too bad around here and I've only been taking it out on clear, cool days for a nice rip.
 
lucky yous the GTi over here has the same low slung sump that catches on just about everything. mines on standard suspension had a few nice scrapes and gouges taken out of it.

whats the laws in canada about retrofitting HIDs ? we cant do it easily over here
 
lucky yous the GTi over here has the same low slung sump that catches on just about everything. mines on standard suspension had a few nice scrapes and gouges taken out of it.

whats the laws in canada about retrofitting HIDs ? we cant do it easily over here

As far as I know, as long as the colors projected from the front end are nothing besides white or amber your safe. Some guys have blue or violet HID's and get pulled over and ticketed, same with blue turn signal markers on the side mirrors. To a certain extent the cops will be lenient, there are some bluish tinted lights that are permitted. You should get a skid plate if your scraping your pan that often ;)
 
no point now the skid plate wouldnt have helped with what happened to it :D
had i looked at lowering it then the aluminium plate was going to be ordered up.

over here we need to have the projector lenses that are disgened for HIDs rather than halogens, auto leveling fitted to the lights and headlight washers.
i looked at it and it was going to cost in the region of £1500 to retrofit them to my bora (jetta mk4 ) £500 was the lights themselves
 
no point now the skid plate wouldnt have helped with what happened to it :D
had i looked at lowering it then the aluminium plate was going to be ordered up.

over here we need to have the projector lenses that are disgened for HIDs rather than halogens, auto leveling fitted to the lights and headlight washers.
i looked at it and it was going to cost in the region of £1500 to retrofit them to my bora (jetta mk4 ) £500 was the lights themselves

^^ ouch on that price PG

part of the problem was so few ordered the OEM Xenons for the bora, plenty for sale on the german ebay but they all left hand

Yea that is rough!! You're lucky :( I would much rather have WOB GTi than a north american one.

I'm ordering a Kamei grille it's goin to look fresh to death. I can't wait to get my new gear on and post some updates.

Anyone got any information on cutting the stock shifter down for shorter throws? I would also have no problem cutting and welding it I work at a tool manufactoring & die shop so I could have it done to precision by one of the machinists.


Got my headlights restored today they look much nicer. Check it out.


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Josh, your post got stuck in the moderation queue because you posted up some pictures, you need to have made 10 posts first! I have approved it for you this time as it's Christmas! :amuse:

T9 man.
 
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the car looks great love the momo stearing wheel how did you restore your head lights i baught one of those restoration kits but it does not work
 
i done my headlights with wet and dry paper then started with the polisher and a cutting pad, the finishing pad.

see here http://www.torquecars.com/forums/f47/my-bora-10747/index2.html#post147784

cut no much more than a inch or so off the internal stick otherwise your knob will just spin unless you can put a groove into it.
i cheated on the box side by using a forge short shifter for a 40% throw reduction
 
the car looks great love the momo stearing wheel how did you restore your head lights i baught one of those restoration kits but it does not work

3M Headlight restoration kit. works perfect if you can follow directions. thanks for the compliment everyone seems to like the wheel.

i done my headlights with wet and dry paper then started with the polisher and a cutting pad, the finishing pad.

see here http://www.torquecars.com/forums/f47/my-bora-10747/index2.html#post147784

cut no much more than a inch or so off the internal stick otherwise your knob will just spin unless you can put a groove into it.
i cheated on the box side by using a forge short shifter for a 40% throw reduction

Thanks for the info. I'll likely just end up buying a short shifter kit from B&M or whatever.

I just put some blue Eurolite LED's in for my war lamps they look nice. I also threw a euro plate and front mount on. check it out.

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Just got a new FK badgeless grill and some kamei eyelids.. not too sure i like the eyelids, opinions? Also got a better pic of my car with the blue lamps in, I got ticketed for them the first night, I have white ones now.

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The notch fillers need to be modified.. the top needs a grind and the bottom peice has a peice that goes into where your bumper screw would go.. that peice needs to be cut shorter to sit better in the hole because right now it's ugly as hell.
 
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Yea I'm not a fan of the grill or the eyelids. I took the eyelids off, put in some 6000k "Crystal White" HID's and replaced the blue war lamps with white ones.. Look a lot better in person as usual but here they are.


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As for the grill I'm ordering a Kamei grill.
 
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Greetings from Toronto Ontario neighbor , we are almost twins , too bad I cannot post any pictures yet, but as soon as I could do that will send it to you, car looks great, I bought mine month ago, all stock, your post gave me some ideas , keep going :$
 
Greetings from Toronto Ontario neighbor , we are almost twins , too bad I cannot post any pictures yet, but as soon as I could do that will send it to you, car looks great, I bought mine month ago, all stock, your post gave me some ideas , keep going :$

Thanks, I'm guessing you're talking about another GTI? If so great, it's an awesome, fun car.
 
Yeap , same color, same trim, rims , the rest is stock, planing todo some upgrades , really happy with this car.

Nice well keep in contact I can certainly give you a few tips and ideas. A simple remap of your ECU can give you a very noticeable increase in horsepower bringing you to about 195hp. I'm working my way towards a K4 turbo and a 42 Drafts Design 3'' Turbo Back exhaust as well as upgrading my intake and adding a Eurojet front mount intercooler but this takes money which takes time to earn while bills are my priority.

Can't wait to see your ride and what you do with it, you'll certainly enjoy it though I'm sure.

Here are two of the latest pictures of my ride, no changes, but they're nice pics.

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dont know if i said this in your post mate but if your looking at a k04 swap, i know i said about the 03s from the later models, then i would be looking at going for a decent turbo.
all the difference would be in the turbo as you would still need to change everything else to make the k04 fit. but
you would have a more reliable turbo
you would also have more power

the 04 even hybridised would only give you around 300 if you were lucky
at gt28 will give you around 350
 
Nice well keep in contact I can certainly give you a few tips and ideas. A simple remap of your ECU can give you a very noticeable increase in horsepower bringing you to about 195hp. I'm working my way towards a K4 turbo and a 42 Drafts Design 3'' Turbo Back exhaust as well as upgrading my intake and adding a Eurojet front mount intercooler but this takes money which takes time to earn while bills are my priority.

Can't wait to see your ride and what you do with it, you'll certainly enjoy it though I'm sure.

Here are two of the latest pictures of my ride, no changes, but they're nice pics.

Looks nice , gonna tint my windows next week,
Will wait for police check, because in Toronto tinted coupes got checked regularly,
Do you guys in Alberta have same immishion test every year or two depends how much you pay?
 
Looks nice , gonna tint my windows next week,
Will wait for police check, because in Toronto tinted coupes got checked regularly,
Do you guys in Alberta have same immishion test every year or two depends how much you pay?

I'm not sure about their emission testing out here I actually only moved here in July from Newfoundland but I haven't heard about it. I also know guys running open headers and different exhausts that wouldn't pass as street legal and all I know is if a cop hears them they get pulled over and ticketed for too loud of an exhaust that breaks a noise bylaw and they often end up getting more for whatever else the cop finds to tag em for like their windows and such. We don't often get pulled over for tinted windows but if the cop pulls you over for something else they usually throw it in there like a bonus and sometimes they scratch your tint with their keys.

I got pulled over when I had those blue LED's and they also got me for my windows and he told me to go home and take it off with a razor blade.
 
I have raised the car to 2'' (leveled the front with the back which was already sitting at 2'' while the front was 1.25'') and replaced both wheel bearings and both inserts for my struts. Today the car is in at Mr. Transmission getting a new Sachs performance clutch it in the car as I burned mine up racing it hard. I have a question, however. I have read that the K03S Turbo can push 23psi and run around 20psi. The default setting is 8psi from the factory and I did not increase boost when the chip was reflashed. Am I able to run a manual boost controllor to run 16 - 20lbs for race and 10 - 12 for street rather than remap the ecu again?

here's some updated pics of the car.


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MBC will confuse the ECU so it will go into limp mode if the boost is outwith parameters off the top of my head i think its about 2 or 3 psi

boost should have been altered when it was mapped
trying to remember what mine ran. think spiked to around 20psi then 18 before tailing off to around 16
 
MBC will confuse the ECU so it will go into limp mode if the boost is outwith parameters off the top of my head i think its about 2 or 3 psi

boost should have been altered when it was mapped
trying to remember what mine ran. think spiked to around 20psi then 18 before tailing off to around 16

Right, I will have to upgrade to a 3'' MAF and a 2.5'' downpipe and exhaust, I've been told AWE makes quality parts for the VW/Audi. 380cc injectors atleast, a larger FMI and then upgrade to stage 2 GIAC performance software.

Some more pics of the car..



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Preparing to head into stage 2 with a 3'' MAF, Eurojet FMI, 42 Drafts Design 2.5'' exhaust, 380cc injectors, GT28RS turbo, GIAC software and a Forge adjustable wastegate. The local shop that's going to reflash my ECU is recommending AWE 2.5'' exhaust for the 1.8T because they specialize in VW/Audi, however, I've never heard of AWE and I've heard great things about 42dd. they're also recommending an N75H valve, opinions?

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I like the car, Will be watching with interest as i might possibly be getting a 2001 vw golf, only 1.6 though, But my friend and i have plans for an ice install project
 
GT28RS with what size housing? What power are you looking for?

My research has made me determine that the Garrett GT28RS would be best for my project but I'm unsure of the housing size. I'm looking for around 300hp, there are built GT-R's and 180sx's I got to compete with these days.. and stock cobalts are pushing 13lbs if i remember correct? gotta keep up with the times.

I like the car, Will be watching with interest as i might possibly be getting a 2001 vw golf, only 1.6 though, But my friend and i have plans for an ice install project

sounds nice, slow car but I'm sure it'll look great I've grown to love Golf's.
 

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