I’m currently in the process of gathering parts for the build and doing research, I don’t want to fit a generation 2 haldex if I can, so I’m currently researching if a generation 4 haldex will be possible, so far things are looking good but I won’t be able to know fully until I wire it into the system.

 

Anyway, let’s start at the beginning, I bought the car originally for the misses to replace her zafira GSI, which I loved I may add, as she got a bit bored after having Zafira’s for nearly 10 years.

 

I found a good looking car at one of the local auctions, so went down to have a look and obviously I bought it 😂 The coolant was a horrible brown colour the battery was flat, it had a scuff on the front bumper and slight impact damage on the rear bumper, so bid the right money and took a chance on it.

 

 

 

Driving it back the next day, the airbag light was on, the temp kept dropping when cruising, and I could hear a rattle in the engine bay, more prominent on tick over when sitting inside the car.
 

I couldn’t even drive it quickly as I knew it was desperate for a cambelt and the rattling noise meant I drove home really steady until I could have a poke around, it did drive lovely although no cruise was a pain.

 

 

Scanned it for faults when home and it was quite clear, passenger side airbag was the fault light so disconnected, bit of cleaner on the contact and back together cleared that fault.

 

Ordered a new battery plus service kit and cambelt kit in preparation of the work ahead.

 

First things first, I can’t stand mucky engine bays, so I clean the engine bay before I start any work usually.

This is how it looked when I opened the bonnet.

 

 

I use neat screwfix degreaser on a warm engine, sprayed with a pump sprayer all over but watching the paintwork, leave to dwell for 10 minutes if possible and wash off with a hose, I’ll repeat if it’s really bad and sometime get in with a brush if it is thick crud.

 

I also replaced the battery, the coolant bottle, done the service and timing belt, flushed the coolant system and replaced the thermostat.

 

 

Took it out and WOW! It was so

quick and punchy for a 200bhp car, i said to my mates that it had to have been mapped and they didn’t believe me, a good mate of mine told me to plug it into VCDS and check and low and behold it had logged the ecu had been flashed once before, so I’m presuming It’s running around the 250bhp mark at stage 1.

 

bit more driving and the coolant was staying clear but the level was dropping and there was no pressure in the system, plus there was signs of coolant down the front of the block, I investigated and found the metal hard pipe wasn’t sealing in the gsf housing properly, so I found a fatter O-ring and it seemed to cure it.

 

I also picked up a puncture for the first time in ages

 

 

I then ordered a new fuel pump tappet to try and cure the rattle in the engine bay as I was still finding my feet with the TFSI engine, it was on its last legs so luckily caught that in time.

 

 

I also picked up a set of 4 Michelin alpin tyres for cheap off eBay and took them to my mate who fitted them and put the car on the hunter alignment machine to check it was all nice and straight and driving true.

 

 

 

 

 

The brakes felt funny from the moment I got the car and had pedal creep, I was hoping the master cylinder wasn’t leaking, so I set about bleeding the brakes and the abs system.
 

After discussion on another forum I found out ESP systems especially, need class 6 dot 4 fluid, the ATE SL6 is a good fluid at a good price.

 

 

plugged in VCDS and put the pressure bleeder on and managed to flush the whole system, the fluid was a lovely black colour 🤣

 

I was still getting a concerning amount of pedal creep even after bleeding but I wasn’t loosing fluid so I kept an eye on things.

 

 

I could still hear this annoying and concerning rattle, the most worrying part was when starting the engine in the morning a could hear the loose chain slapping and I was concerned it may jump a tooth.

 

I ordered an INA repair kit with the tensioner and chain, the tools to do the job and the bolts and gaskets then plucked my courage up as I knew the tensioner bolt was a pain.

 

 

first attempt didn’t go well, the locking tool I bought just bent the pins out, as I was already in this too far I wondered if I could weld it back together, so out came the MIG and I just leathered weld round the pins and plugged the top.

 

crossing my fingers I went at it again, luckily the tool held and the bolt came out with no drilling involved 😀

 

 

This is the screw that holds the big metal pins in that take all that force to undo the bolt, it just sheers out and the pins just bend out in one nice flowing motion as your turning the breaker bar. 🤣

 

It was nice to see that the original Audi tensioner is also an INA item 👍

 

 

The welding I did round the pins, excuse the mess I’m still learning and I wasn’t taking any sort of care, I just wanted it to do it’s job.

 

 

Fired it up and the horrible rattle has gone thank god, so now I don’t have to worry about the engine self destructing any more.

 

I was under strict instructions to repair the PDC system too, luckily there was no error codes, during the impact on the rear bumper it popped one of the sensors inside but also took the fixing bracket with it.

 

So the bumper came off, I fished the sensor out, re-stuck the bracket to the bumper and it was all working again.

 

 

 

 

 

 

Edited 15 February, 20206 yr by Vrsburnzy

nice work!

 

I hope your winning bid was low enough to reward the punt that you took.

 

How can one tell from within VCDS if the ECU has been reflashed?

 

Would a remap show any differently to say the dieselgate "fix"?

I bought a TFSI K04 for another project but things have changed so it’ll be destined for the Octavia now, it needs rebuilding but I’ll just put a new CHRA into it and it’ll be as good as new again.

 

 

The rear wiper doesn’t work and it’s corroded like they all do, I have an A6 daily and I stripped the motor down rebuilt it and fitted some seals to stop it leaking into the housing and it worked fine, I set upon the Octavia motor and it was just too far gone, I got it working again but it was not engaging the gears properly so I’ll just buy another second hand motor and make 1 good one out of the 2

 

 

 

The coolant loss was still an issue, I could still see signs of coolant down the front of the block so I ordered a new genuine housing from TPS, which I should of done in the first place, but in all honesty the stat was working fine temperature wise it just wasn’t sealing, I took the GSF stat off and could see it wasn't seating in the hole properly, new genuine stat fitted and it held the correct pressure and no coolant loss, it was still lovely and pink so I assume the horrible brown coolant was either very old stuff or they have mixed two types of coolant.

 

 

Not a job I looked forward too as it’s buried behind the alternator and the connecting pipework is a pain to pull out the way although I got better at it towards the end 😂

 

 

 

Nearly finished catching up to date 🤣

 

I’ve been looking at the 2.5t Mondeo for some time now, I recently sold a few cars, so made space and got some money back 😂 I seen one at the auction again, went to view and it was an amazing spec with the titanium X sport body kit fitted, so again I bid what I thought was fair and won it for a very good price.

 

The misses really liked the car and all the toys it’s got so it’s currently destined for her, after I’ve run it a bit and making sure I’ve ironed out any issues and had my fun driving it I’ll pass the keys over.

 

 

BUT! This means I have the Octavia surplus to requirements, and it’s a great little car, I had a mk1 TT intending to be a track car but couldn’t get along with it as I’m such a tall bloke so that is also going, plus my only gripe even at 250bhp is putting power down is comical in the Octavia.

So project 4x4 was put into action, I first went though elsawin and etka to see if it’s even mildly possible, and a Gen 2 is fairly bolt on minus the wiring that is, but I didn’t want a Gen 2 I wanted a Gen 4 haldex, so out came the laptop and I did more research.

 

It still seems fairly possible but there’s lots of unanswered questions, I went looking for a Gen 4 haldex and managed to find one along with a compatible subframe and rear end for a very good price in the Peak District, so not only did I get cheap parts I also got a nice drive out 😎

 

They very kindly fork lifted it into my A6, excuse the orientation.

 

I got it home and set about stripping it, for two reasons, One, so I could now get it back out the car 🤣 and Two, so I could clean and rebuild all the bits ready for fitting eventually.

 

 

So that’s where we are at now, it’s not going to be a fast project, it’s also not my only project but I hope to plug away at it during the summer, and see where it takes me.

 

👍

 

I may have missed a few bits in between too, the car started to feel slow and jerky on WOT and found out the DV was gone, replaced that and power was back to normal.

 

Also the button for the central locking wasn’t working after I repaired the trapped wires in the handbrake mech setting the central locking mad whilst driving so fitted a new spurious button and that’s also working fine.

 

Its just been used in daily duties at the moment, and doing a very smart job of it too, I’m also really impressed with the way it drives when pushing on, for such a big car it’s very nimble.

 

edit: oh and I fitted cruise control, for the sum of around £15 iirc 🤣 just a second hand stalk and luckily the steering controller was cruise capable so a fairly easy retrofit and much better for longer motorway journeys 😎

Edited 15 February, 20206 yr by Vrsburnzy

35 minutes ago, J.R. said:

nice work!

 

I hope your winning bid was low enough to reward the punt that you took.

 

How can one tell from within VCDS if the ECU has been reflashed?

 

Would a remap show any differently to say the dieselgate "fix"?

 

Thanks, I paid a lot less than anything on eBay or AT at the time, and let’s be honest anything you buy in this price range will require some tidying, so yea I’d say I’ve done ok, it wasn’t a steal like the Mondeo was but I’ve ended up with a much better car, anything VAG and BMW seems to demand good money at auctions nowadays.

 

Go into engine on VCDS and open Advanced ID let it load and it’ll come up with a screen like below, it shows the amount of successful flash attempts, whether it also detects dealer flashes I wouldn’t know.

 

I had to take a screen shot as a good mate of mine who runs his own business repairing and working on performance VAG cars didn’t believe me, once I shown him the screen shot he said it had been mapped.

 

Thanks

 

I have seen that before but there is so much in VCDS that you can only retain that which you think is relevant to the problem that you have.

 

I will be getting the Yeti remapped, it has already had the dieselgate "fix" so will check the flash status before and after the remap, it may show 1 for the fix and then 2 after the remap.

 

Its probably of relevance to the debate about whether the dealers can tell if a car has been remapped regarding warranty or insurers looking to refute a claim.

I'll be keen to see how you get on with this. It looks like an exciting project!

 

Kirkynut 

Thanks Kirky

 

I'm looking forward to it, it’s taken a back seat at the mo, the other half is still using the car as a daily, I've got to find her a VRS in blue as a replacement first🤣
 

plus with this Woohan and everything going on I’ve not been spending unnecessarily as I’m self employed and I’m most likely going to be affected if we have to stay indoors.

 

i have had the rear subframe powder coated, along with a few other bits, I also have a B5 S4 which I’m investing some time in again as it’s also been on the back burner whilst I focussed on other projects.
 

the two too subframes are b5 ones, the bottom one is the one for the Octavia, I’m just waiting on the other bits to get done.

 

next purchase will be a full poly bush kit, then I can install the subframe, with all the bits, I’ve got a tank and gearbox on my watch list so these will also need to be purchased as soon as things blow over.

 

other than that the Octavia has been OK, airbag light is on again, passenger seat connection so I’ll take a look, the other half has reported it taking longer to start on first cold start but every time I’ve been in it it’s been fine 🤣🤦🏻‍♂️

So passenger seat air bag fault was in fact drivers side crash sensor 🤣

 

luckily it’s a well documented fault so I had it located quickly, and as well documented on here, it was broken wires in the door shut.

 

the two red through crimps where a previous repair that had failed.
 

 

All fixed and ready to put back together, I do have loom tape but I’ve put it somewhere safe 🤣

 

 

Grommet back on and fault cleared straight away so that was nice and painless.

 

So with the current situation going on in the country I’m sure a lot of us are trying to keep busy, as the Octavia is black and the paint has been well weathered I thought I’d have a go at mopping the paint.

 

its not perfect but it’s a damn site better than it was, it’ll hopefully be easier to wash and keep looking clean now too.

 

took me 2.5 days in total, wash and dry, clayed, 3m advanced cutting compound, super resin polish, and then extra gloss protection on top. I’ve got some splatter to clean off some rubber items but I’ll attack that another day.

under fluorescent light you’ll still see scratches and other imperfections, the roof is particularly bad, it looks like loads of little bird poo etchings on the roof, it needs something stronger than I had to cut it back but I just made it look clean for now, but it’s giving a good reflection.

 

I'm by no means a pro at this but I think it’s come out ok.

 

 

On my way to the shops for essential travel I took a slight detour so I could quickly snap my hard work before it gets dirty again, I’ve also got to say this car is so much fun to drive in standard form.

 

 

 

 

it beads beautifully now, just have to keep on top of it

 

 

As I said above I’ve got some cleaning up to do from the 3m compound and I may detail the engine bay and the plastics if I get bored again, but that’ll be it for now whilst we are under lockdown.

Good effort! I hope that you are not too financially knackered from this Coronavirus business. It's a bloody nightmare!

 

I think it's good that we have a hobby in cars as you need something to keep you sane! 

 

I've just sold a black car and vow never to have another as they're so hard to keep looking clean but they don't half look good when they're clean and polished!

 

Kirkynut 

Thanks for the kind words Kirk, I’m self employed so currently not doing great out this situation but I’ll make it through hopefully.

 

I've got a neighbour that his timing belt snapped on his TT so I’ll repair that on my drive just to help pay some bills.

 

yea I’d of gone mad if I didn’t have anything to tinker with, I go into my own little world and just crack on with the job, plus I get a lot of satisfaction when I’ve finished something so that keeps me interested 😁

Well I’m sure I’m not alone with having a bit of a bumpy ride whilst we work our way through this pandemic.

 

I've had quite a lot change over the last few weeks but this project hasn’t died a death and I’m still very much looking forward to getting spanners out and onto the car 😎 there is going to be a few surprises in the next few weeks I’m hoping.

 

I got a message to say my stuff has all been powder coated now so that’s great news 😎

 

in the mean time I’ve kept myself busy, my S4 has been needing some love as the engine I installed had a leaking head gasket that I wasn’t informed about, and it done my head in, so I set about fixing that, along with taking the bigger k04 turbos off and putting original k03’s back on but rebuilt with new cores.

I spent a whole week rebuilding the heads, cleaning the valves and lapping them and then rebuilding them.

 

then stripped my bay down to this.

 

 

then spent what felt like an eternity cleaning and putting back together to get here.

 

 

and last few bits to get nearly done.
 

 

all went back together and drives lovely now, I’ll continue to work on this car but it’s at a position now where I can just jump in, turn the key and go out and enjoy it and have some fun, it’s stage 2 mapped with flat shift and launch so it is good fun 😎

 

I then had the TT over to fix, if your bored then here is the thread I made on the TT forum, bit of bedtime reading 👍

 

https://www.ttforum.co.uk/forum/viewtopic.php?t=1963363

 

 

then I had a mate pop over and wanted his timing belt and service and a few bits doing so set about with that, trying to fix an oil leak and found his camshaft was knackered so he had me replace that 🤣

 

Please excuse the orientation.
 

old

 

removed

 

new

 

so that’s taken me up until recentlyish, Mondeo is now up for sale, misses didn’t like it and it’s not an estate so I couldn’t use it for work which I was gutted about ☹️

 

Great Thread.  Any updates on the project?

Right everyone, been a lot happening in my life over the last few months

 

but I can happily say project Octavia is back, slight change of direction but for the better

 

i pick this up on Saturday all going well  

 

 

Nice! I saw it being advertised for a while, hope you got it for a good price.

Thanks, well it’s cheap enough, but never as cheap as I would of liked it 🤣 car prices are high currently, I’d of liked an MQB chassis but they where way too pricey for my needs and with track season and good weather coming soon I wanted something to drive esp with ring trip planned too, it was the cheapest for sale in the country currently so that’s as good as I can do, plus my old A6 daily is getting chopped in for it so with work being manic it’s just a lot less aggro 🤣

 

can’t wait to get my hands on it now and start doing stuff and getting prepped for 4wd conversion and 420bhp hopefully 😈

 

I just sold my MK2 VRS, probably cheaper than I should have. 

 

Are you going for a K04 conversion or K04 Hybrid?

 

 

Was it TDI or TFSI? TFSI DSG cars are fetching real good money at the mo 🤦🏻‍♂️ 
 

I've been told I can make 420 on a k04 iirc, I have one to rebuild already, just need S3 injectors, induction kit, and 3” catless DP, I’ll have to txt him again for a shopping list tbh 🤣 he’s also doing my mapping 👍

https://www.facebook.com/marketplace/item/445711349900461

The full spec is in the advert.

 

It was a TSI and manual, I just had the turbo rebuilt in November by AET to the 370 hybrid spec, would have easily got 400bhp after a remap i think.

 

The engine in your new one is a TSI (EA888) not TFSI (EA113), apologises if I'm trying to tell you stuff you already know.  As for S3 injectors if its from an 8P/TFSI then they wont fit. 

So far I heard and was going to test this theory out, the Mk7/7.5 Golf R/ EA888 Gen 3 injectors should fit - I was planning in buying some 2nd hands from ebay and getting them cleaned and resealed.

 

The current injectors in the CCZA engine max out at around 370bhp.

 

 

 

i thought the standard K04 will max out 360 - 380bhp unless its a hybrid of course

Looked a nice motor, and yea I was after the TSI motor for a particular reason, just my mistake on the terminology 😬 

 

I asked my mate after writing on here and I need, a K04, set of injectors, inlet pipework, and most likely a 3” decat to see 420, he reckons it will flow that so I’m not sure, he’s not wrong very often 🤷🏻‍♂️ And is a VAG specialist

 

 

I asked Pip from the Fuel Injector Clinic / R-Tech about them and he said the TFSI injectors wouldn't fit a TSI. 

Also I got a response from Alex Kerr (AKS Tuning) stating that the GEN3 EA888 TSI injectors would fit. 

 

That made sense to me as if you check the Bartek website (RMTG aswell) they have 2 sets of uprated injectors, one for the EA113 TFSI and the other for EA888 TSI.