My Mk2 GTI project

Tom_vRS · 04-08-2006, 13:04

Link to discussion thread HERE

Well, here it is the day my brother bought it. Was only back in November 2005. It was sat under a cover on my grandads drive for 6 months really quite unloved as the clutch had gone at 99989 miles. As the pictures show, its pretty grotty after its quick blast with the jetwash.

Its still on its original plates too!

The small bumpers look nice, definitely going to keep them on, although they need steam cleaning and some serious nourishment... Bring on the swissol!

Grandad fitted a towbar to take his little trailer to the tip. But it will be coming off. I also want some OEM tinted lights to smarten up the back end, and fit the rear wiper so it lays flat.

The mileage... grotty dash pod including suspect OAP hair on dash.

Pretty grotty, but still tidy interior...

And the original P slot wheels. Think they will be staying if they clean up nicely. If not will source some BBS replacements...

I had a new clutch fitted at Mr Clutch, and a new battery as it wouldn't hold charge. The auxilliary drive belt was squeeling, so that got replaced too.

Grandad had fully serviced it not too long ago including fitting a replacement cambelt. This needed tensioning as it was flapping about making a right din, so did that too.

Although it flew through the MOT, I'll get a few things I've picked up done at the earliest opportunity. Been quoted £160 from an independant local garage...

CV boot
Small length of corroded brake pipe
both front wishbones - rear bushes non existant (really shouldn't of passed mot imho)From what I can see so far it need:
New heater matrix (coolant in the footwell)
Replacement heater matrix flow and return pipes to get rid of VWs bypass valves that don't work.
Strip and rebuild the front seat bases so they work smoothly
New heater motor resister pack as fan speed 2 is the only one that works
2 new door pins.
Door boots/grommets to conceal the wiring for the aftermarket central locking thats fitted
upgrade to door speakers
gear shift repair kit - reverse is easily selected instead of first
gear linkage repair kit to sort the slightly sloppy change
new dash surround as thieving scum broke it when pinching the cd player
shampoo the interior
new multi function switch as rear wiper on permanently
new lock set as the ignition barrel has packed up
remove the cack aftermarket alarm
remove the towbar
fix the heated rear window
fit PAS

Will keep this updated as things progress!

Update:

Right, ripped out the lower part of the dash tonight, as well as the a-pillar trims.

The plan for tomorrow is to fit the gear lever repair kit which will solve the problem of getting 1st instead of reverse. Also plan to remove the cheapo alarm and strip the stering column ready to change the ignition barrel, and remove the rest of the dash ready for a frigging good shampoo of the carpets and chaning the heater matrix and replacing the dash surround.

Progress at last!

More Progress:

Out came the dial pod, centre console, glove box and then dash! Was a little fiddly, but got there in the end!

Ready now so I can change the heater matrix including feed and return hoses (to delete the carp bypass valves).

I've decided I'm going to strip the entire interior, and only refit parts I'm happy are a) going to last, b) in good condition, c) original and d) clean - the whole interior is pretty grotty.

Just look at all the wires!

I've also discovered that the OEM loom has been chopped about no end to accomodate a cheapo rubbish aftermarket alarm, and also for the headunit. I'll repair these looms as best I can, and just leave the professionally fitted TOAD Cat2 immobiliser in place.

More progress:

Well, bought myself a Haynes, downloaded a few guides and bought me a proper socket set (Halfords Professional 90pc)

On order from GSF car parts:

heater matrix
both steering column stalks
feed and return hoses
electric wing aerial
resistor pack for the fan speed
Gear linkage repair kit From VV I now have the gear shift repair kit.

From eBAY:

Door grommits to conceal wiring
fuse box lid
mfa switch/wiper stalk - FAULTY but already left +ve feedback. Dammit.
resistor pack for fan speed - FAULTY but already left +ve feedback. Dammit.
Relacement door pins. All I need is for it all to arrive and I can get tinkering again!

Also bought some glass cutter... will be taking before and afters, dont think they've been cleaned for 19 years!

Tom_vRS · 04-08-2006, 13:17

Things have come on a little since.

Tom_vRS · 04-08-2006, 13:41

Things have come on a little.

The gear shift repair kit has now been fitted. The shift housing had worn so much you could see through it! It resulted in getting reverse instead of first far too often. The car feels so much safer to drive now!

The heater matrix and feed/return hoses have now been replaced. Alas I now have a heater!!

The resistor pack for the heater fan has been changed, so the blower works on all settings now.

. The dash is now all back in, with replacement switch surround, and a new rev counter too... the interior looks respectable again.

Next on the list is a new ignition barrel and steering lock/housing... then I'll be able to turn the steering wheel and start it with the key rather than a screwdriver. I can't wait!

Tom_vRS · 04-08-2006, 16:12

Update: Just ordered an ignition barrel, steering lock housing and some door membranes from gsf.

So I should have a fun evening next week trying to code the new lock to the original keys... can't wait

Tom_vRS · 09-08-2006, 14:11

Hmmm, not much progress, other than:

The steering lock housing arrived from GSF. The casting was broken and the top bearing very rough, so I sent it back and bought a new one from VW yesterday, much better. The ignition lock cylinder hasnt arrived yet - cant wait as when thats in it will be drivable on the road again!

I took a wee pic of the engine bay - overall not too bad for a 20 year old car.

However - the cold start injector (on the right of the inlet manifold) appears to have a bodged plug, so until I can be bothered to head over to VW again to source a replacement, 2 spade connectors will have to do...

And the vacuum hose from the inlet manifold to the cam cover is way oversized in diameter, and held on with a silly sized jubilee clip - so I'll be stopping at my local motor factors on the way home tonight for some replacement hose - and I've just ordered a replacement breather bung for the rocker cover, as it doesn't attach very well at all...

Fingers crossed it will be back on the road by the weekend - just need to insure and tax it - then off for an MOT

I know it will fail on:

Perished CV boot
Perished brake flexi hose

I bloody well hope that's it though!

Tom_vRS · 15-08-2006, 00:00

Well, had it insured and on the road for a few days now, and a few problems have reared there head... so I'm taking a no-nonsense approach - full resto coming up.

Need to get everything ordered and start fitting it all so it can be MOT'd end of Sept and on the road pukka for when my vRS goes back first of October...

Got a hell of a lot to do before then though...

Can't fault it really - but its someway off being a reliable daily hack. Trying to get it mechanically perfect. Basically overhauling the whole cooling system inc water pump and new heater matrix, going to recon the oil pump and clean pick up pipe and sump etc, will be cleaning the old tappets up a treat, need some vacuum hoses, a few senders, clean the ISV, new cambelt and tensioners, oil and filter change etc...

Then I need new brake flexi hoses all round, will recon the callipers, new disks and pads, may give the callipers a lick of silver paint too.

Then the suspension - new bushes, shocks and springs all round, top mounts etc... Need new CV boots too.

The exhaust could do with replacing - wonder how much a genuine system is.

Then onto the interior - got a saggy drivers bolster (material is fine), needs a good shampoo, get a leather gear gaitor and sort out a stereo system - but need door pods, dash speakers are pants. Gonna convert to bee-sting aerial too.

Then the exterior, got a new screen to go in, new seals all round, refurb the wheels with new tyres, and a possible partial respray too. Got to attack the bumpers with a heat gun and remove the towbar.

And after a total spend including the car of probably close on £2500, i'll have a car worth around £1000... lol. Should be good for another 100k of pretty reliable motoring, so will be worth it in the long run!

04-08-2006, 13:04	#1
Tom_vRS Briskodaholic Join Date: Dec 2004 Location: Fenland, Cambridgeshire Posts: 11,559 Members Car: '97R BMW 328i Saloon Thanks: 679 Thanked 436 Times in 313 Posts	My Mk2 GTI project Link to discussion thread HERE Well, here it is the day my brother bought it. Was only back in November 2005. It was sat under a cover on my grandads drive for 6 months really quite unloved as the clutch had gone at 99989 miles. As the pictures show, its pretty grotty after its quick blast with the jetwash. Its still on its original plates too! The small bumpers look nice, definitely going to keep them on, although they need steam cleaning and some serious nourishment... Bring on the swissol! Grandad fitted a towbar to take his little trailer to the tip. But it will be coming off. I also want some OEM tinted lights to smarten up the back end, and fit the rear wiper so it lays flat. The mileage... grotty dash pod including suspect OAP hair on dash. Pretty grotty, but still tidy interior... And the original P slot wheels. Think they will be staying if they clean up nicely. If not will source some BBS replacements... I had a new clutch fitted at Mr Clutch, and a new battery as it wouldn't hold charge. The auxilliary drive belt was squeeling, so that got replaced too. Grandad had fully serviced it not too long ago including fitting a replacement cambelt. This needed tensioning as it was flapping about making a right din, so did that too. Although it flew through the MOT, I'll get a few things I've picked up done at the earliest opportunity. Been quoted £160 from an independant local garage... CV boot Small length of corroded brake pipe both front wishbones - rear bushes non existant (really shouldn't of passed mot imho)From what I can see so far it need: New heater matrix (coolant in the footwell) Replacement heater matrix flow and return pipes to get rid of VWs bypass valves that don't work. Strip and rebuild the front seat bases so they work smoothly New heater motor resister pack as fan speed 2 is the only one that works 2 new door pins. Door boots/grommets to conceal the wiring for the aftermarket central locking thats fitted upgrade to door speakers gear shift repair kit - reverse is easily selected instead of first gear linkage repair kit to sort the slightly sloppy change new dash surround as thieving scum broke it when pinching the cd player shampoo the interior new multi function switch as rear wiper on permanently new lock set as the ignition barrel has packed up remove the cack aftermarket alarm remove the towbar fix the heated rear window fit PAS Will keep this updated as things progress! Update: Right, ripped out the lower part of the dash tonight, as well as the a-pillar trims. The plan for tomorrow is to fit the gear lever repair kit which will solve the problem of getting 1st instead of reverse. Also plan to remove the cheapo alarm and strip the stering column ready to change the ignition barrel, and remove the rest of the dash ready for a frigging good shampoo of the carpets and chaning the heater matrix and replacing the dash surround. Progress at last! More Progress: Out came the dial pod, centre console, glove box and then dash! Was a little fiddly, but got there in the end! Ready now so I can change the heater matrix including feed and return hoses (to delete the carp bypass valves). I've decided I'm going to strip the entire interior, and only refit parts I'm happy are a) going to last, b) in good condition, c) original and d) clean - the whole interior is pretty grotty. Just look at all the wires! I've also discovered that the OEM loom has been chopped about no end to accomodate a cheapo rubbish aftermarket alarm, and also for the headunit. I'll repair these looms as best I can, and just leave the professionally fitted TOAD Cat2 immobiliser in place. More progress: Well, bought myself a Haynes, downloaded a few guides and bought me a proper socket set (Halfords Professional 90pc) On order from GSF car parts: heater matrix both steering column stalks feed and return hoses electric wing aerial resistor pack for the fan speed Gear linkage repair kit From VV I now have the gear shift repair kit. From eBAY: Door grommits to conceal wiring fuse box lid mfa switch/wiper stalk - FAULTY but already left +ve feedback. Dammit. resistor pack for fan speed - FAULTY but already left +ve feedback. Dammit. Relacement door pins. All I need is for it all to arrive and I can get tinkering again! Also bought some glass cutter... will be taking before and afters, dont think they've been cleaned for 19 years! __________________ 97/R BMW 328i in Boston Green. Last edited by Tom_vRS; 04-08-2006 at 13:23. Reason: Just tidying it up.

04-08-2006, 13:17	#2
Tom_vRS Briskodaholic Join Date: Dec 2004 Location: Fenland, Cambridgeshire Posts: 11,559 Members Car: '97R BMW 328i Saloon Thanks: 679 Thanked 436 Times in 313 Posts	Re: My Mk2 GTI project Things have come on a little since. __________________ 97/R BMW 328i in Boston Green.

04-08-2006, 13:41	#3
Tom_vRS Briskodaholic Join Date: Dec 2004 Location: Fenland, Cambridgeshire Posts: 11,559 Members Car: '97R BMW 328i Saloon Thanks: 679 Thanked 436 Times in 313 Posts	Re: My Mk2 GTI project Things have come on a little. The gear shift repair kit has now been fitted. The shift housing had worn so much you could see through it! It resulted in getting reverse instead of first far too often. The car feels so much safer to drive now! The heater matrix and feed/return hoses have now been replaced. Alas I now have a heater!! The resistor pack for the heater fan has been changed, so the blower works on all settings now. . The dash is now all back in, with replacement switch surround, and a new rev counter too... the interior looks respectable again. Next on the list is a new ignition barrel and steering lock/housing... then I'll be able to turn the steering wheel and start it with the key rather than a screwdriver. I can't wait! __________________ 97/R BMW 328i in Boston Green.

04-08-2006, 16:12	#4
Tom_vRS Briskodaholic Join Date: Dec 2004 Location: Fenland, Cambridgeshire Posts: 11,559 Members Car: '97R BMW 328i Saloon Thanks: 679 Thanked 436 Times in 313 Posts	Re: My Mk2 GTI project Update: Just ordered an ignition barrel, steering lock housing and some door membranes from gsf. So I should have a fun evening next week trying to code the new lock to the original keys... can't wait __________________ 97/R BMW 328i in Boston Green.

09-08-2006, 14:11	#5
Tom_vRS Briskodaholic Join Date: Dec 2004 Location: Fenland, Cambridgeshire Posts: 11,559 Members Car: '97R BMW 328i Saloon Thanks: 679 Thanked 436 Times in 313 Posts	Re: My Mk2 GTI project Hmmm, not much progress, other than: The steering lock housing arrived from GSF. The casting was broken and the top bearing very rough, so I sent it back and bought a new one from VW yesterday, much better. The ignition lock cylinder hasnt arrived yet - cant wait as when thats in it will be drivable on the road again! I took a wee pic of the engine bay - overall not too bad for a 20 year old car. However - the cold start injector (on the right of the inlet manifold) appears to have a bodged plug, so until I can be bothered to head over to VW again to source a replacement, 2 spade connectors will have to do... And the vacuum hose from the inlet manifold to the cam cover is way oversized in diameter, and held on with a silly sized jubilee clip - so I'll be stopping at my local motor factors on the way home tonight for some replacement hose - and I've just ordered a replacement breather bung for the rocker cover, as it doesn't attach very well at all... Fingers crossed it will be back on the road by the weekend - just need to insure and tax it - then off for an MOT I know it will fail on: Perished CV boot Perished brake flexi hose I bloody well hope that's it though! __________________ 97/R BMW 328i in Boston Green.

15-08-2006, 00:00	#6
Tom_vRS Briskodaholic Join Date: Dec 2004 Location: Fenland, Cambridgeshire Posts: 11,559 Members Car: '97R BMW 328i Saloon Thanks: 679 Thanked 436 Times in 313 Posts	Re: My Mk2 GTI project Well, had it insured and on the road for a few days now, and a few problems have reared there head... so I'm taking a no-nonsense approach - full resto coming up. Need to get everything ordered and start fitting it all so it can be MOT'd end of Sept and on the road pukka for when my vRS goes back first of October... Got a hell of a lot to do before then though... Can't fault it really - but its someway off being a reliable daily hack. Trying to get it mechanically perfect. Basically overhauling the whole cooling system inc water pump and new heater matrix, going to recon the oil pump and clean pick up pipe and sump etc, will be cleaning the old tappets up a treat, need some vacuum hoses, a few senders, clean the ISV, new cambelt and tensioners, oil and filter change etc... Then I need new brake flexi hoses all round, will recon the callipers, new disks and pads, may give the callipers a lick of silver paint too. Then the suspension - new bushes, shocks and springs all round, top mounts etc... Need new CV boots too. The exhaust could do with replacing - wonder how much a genuine system is. Then onto the interior - got a saggy drivers bolster (material is fine), needs a good shampoo, get a leather gear gaitor and sort out a stereo system - but need door pods, dash speakers are pants. Gonna convert to bee-sting aerial too. Then the exterior, got a new screen to go in, new seals all round, refurb the wheels with new tyres, and a possible partial respray too. Got to attack the bumpers with a heat gun and remove the towbar. And after a total spend including the car of probably close on £2500, i'll have a car worth around £1000... lol. Should be good for another 100k of pretty reliable motoring, so will be worth it in the long run! __________________ 97/R BMW 328i in Boston Green. Last edited by Tom_vRS; 15-08-2006 at 00:02.

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