Start To Finish - 400+BHP Golf MK5 R32 Turbo Build

welcome back guys today we're going to look at the entire turbo build from start to finish to the point where it was off at the mappers because if any of you guys have seen my other videos I had some issues after the mapping so I didn't include it in this video but this will be essentially you know start to finish off turbo in your R32 it's a long video and I appreciate it if everyone can stick around and watch to the end um I put a lot of time and effort into this you know recording there's hundreds and hundreds of hours of recording so really appreciate if you can stay to the end and don't forget to hit that like And subscribe guys and leave me a comment down below of anything you might want to say you might want to know all you want me to do so have a great Christmas guys this is probably the last video until the new year so if I don't drop another video before have a wonderful Christmas everyone and I'll see you in the new year so all I'm doing here guys is I'm removing the front end of the car this will include the radiator the condenser the whole front support draining all the fluids and uh and removing the headlights Etc this gives me access to the inlet manifold because the bolts aren't accessible with all this stuff in place I need to remove the inlet manifold to get access to the head and also to fit the short Runner intake [Music] foreign [Music] just quickly removing the vacuum lines of the vacuum station then runs all the flaps inside the inlet manifold and now I'm just simply trying to go through and methodically see a check everything that's connected to the internet manifold before I can remove it foreign [Music] managed to get the exhaust and bolted from the head and I think you know in that manifold and everything off so next job will be taking the head off cleaning up put the spacer in Bolt it back down and get all the kit fitted foreign [Music] [Applause] [Music] TDC and then take the chain gears off and then rip the head off we can see me doing here guys it's taking the bolts from the side timing cover that's on the head side there's a few bolts around the casing to get it off and I've just taken off the tensioner for the chain [Music] what I'm doing here guys is I'm removing the phase gear you need a 32 month spanner to hold the cam in place so you can undo the bolt on the on the face pocket [Music] foreign [Music] bolts off chains three we can remove the head bolts and get the head off and there's the header [Music] so I'm just checking the Pistons over and the Piston was here and looking for a large amounts of carbon buildup or any damage to the Pistons or the Piston walls that might mean I need to rebuild the engine instead of just having the headspace soon [Music] so a really crucial part of the build is to make sure that the head gasket can seal properly with the spacer so you need to be really really really thorough and careful when trying to clean up the head lots of people get their heads skimmed just that principle um I saw that CEO Motorsports another great YouTube channel that I follow didn't do theirs with it on their Mark for R32 turbo and this car is never overheated at all um so I know that the head is in good condition it has it's not warped as such so I didn't see the need to you know essentially reduce the life of this head by getting its skin needlessly because if you're getting this game anyway then you're gonna be you know taking life off this head so I didn't need to do that I just thoroughly cleaned everything up and made sure that all the surfaces were smooth and clean and didn't have any build up in there just let me be and the same as for the block face before I put the head on as well such a disgrace I never really asked to be brought into this place you wanna love me well then baby have a taste all the highs and the lows now you'll never be the same I don't really wanna hurt you but I can't control the pain if you're sticking by my side maybe I went for some Bosch 550 CC ejectors here I'm just replacing the original injectors with the new boss ejectors it's a fairly simple installation process you lift the clip off you put the new one in and you put the clip back down I know you told your friend you're not okay [Music] [Music] fade away three two one Ulta it's not magic we're all in there I'll leave the cats on until next minute [Music] so I can't really see a fitment issue I'm down in this corner here and as you guys can see but in that corner there there's a fitment issue so I can't you know I can't put the head on the I'll put the manifold on I'm just gonna test it manifold now enough yeah so just test fit it and see anything we need to buy for it and see whether it fits [Music] but I've known you too long okay that's good we do have to remove the bracket here which is the uh bracket there I might just trim the manifold a little bit so it doesn't interfere with it or trim something so it doesn't interfere with it anyway so that looks like it fits fine so get the bottle body on there and then one thing to note the bolts are too long so they will need to be cut down thought about I'd say a centimeter so to get the inlet manifold to fit onto the head this uh bracket here for the engine hoist these bolts here hit against the corner here so basically what I've done is I've taken a mil bit you can just get off eBay and just trim down the aluminum the aluminum does does sort of trim now very quickly and very easily so it's trim down the corner there and then that now clears over that Bolt shouldn't cause any issues um there's plenty of ceiling service here so the next thing I need to do is get the throttle body off the original Inlet manifold while I've got it off I might as well give it a good clean get rid of any carbon buildup that that's occurred over time and essentially I'm going to have to create a gasket for this the original gasket is part of the inlet manifold so I've got some one millimeter gasket paper here which is a thermal gasket paper it can withstand high heat and cut in the holes and then cutting it to shape of the throttle body [Music] thank you [Music] so here we have our gasket this is three three layers if you've got one side for the gasket you've got the spacer plate in the middle and then the other side is the other side of the gasket I think you can get it the wrong way around there's only one way it goes it's orientation so just gonna lay it on there and see everything lines up perfectly some of the Styles so now you're very important you want to make sure that all the oil holes and the water holes all line up and a good way of doing that is to put the old gasket over the top I'll tell you if you've got any holes that aren't aligned will have them been cut out because if you see any uh hot you know holes in the gasket but not in the space head gasket you know that it's it's not right and from what I can see I can see every hole so that looks absolutely fine take that one off now get the head on [Music] foreign [Music] [Music] [Music] foreign [Music] you can see I put a bit of yellow paint on one side of the nut so originally I put on this side here and then after done my 290 degrees you can see this facing that way so you can see all the nuts facing the right direction so I haven't missed any it's a really good way of checking to see if you've missed any and that all looks good so the camera wasn't recorded when I feared the injectors in the rail just I lubed up each injector with a little bit WD-40 and I slid right in there and then just did the bolts up as you can see this injector outfitted this was definitely something that I wish I'd have done right at the end I didn't know how easy it was to take the cam cover off once you'd finished the build but it quite literally has three minutes to get it off so definitely would have waited until after the build to do this bit foreign [Music] chain I've got the cover back on I painted this gold color I'm not too sure on it yet but what do you guys think about it let me know in the comments if you like it or not the manifold is going black so it's the Boost pipes so maybe that will help the look of it as well so I just got them Loosely bolted up at the moment and there's no gasket or anything in there it's just for mocking purposes see what it looks like see where I got to run the lines for and any issues any clearance issues I need to sort out so let's get it on the car and uh see what it looks like foreign just holding it on so that's the exhaust that's how it was set it's a lot lower than I was expecting but yeah she's in here was my first attempt at fit in the downpipe from Laurent Motors it doesn't fit at all I had to really modify it to get into fit so I definitely avoid buying one of those from malaria Motors so I have lengthened the wires for the sensors here so that I could run the loom on the opposite side of this pipe so originally this Loom here would run this side of the pipe the throttle body hits so I've extended these sensors probably by about six inches five or six inches and just so I can run them on the other side of the pipe so that will clear for the throttle body for the sensors and then I just need to put the banjo bolt in this piece here because I can no longer use a straight edge so I'll do that now get the inlet manifold on drop down and that is all fitted as you can see I had this shave off a little bit just behind here and you guys can see literally like a millimeter just so that the collar of this wasn't hitting the plastic bit but yeah all done [Music] thank you [Music] so here I'm making the water feed lines and the water return and also the oil returned from the turbo these are all an PTFE fittings and all reusable fittings in hindsight it is probably better measuring the fittings you need and going to a local specialist and get them to make the hose for you they'll make it a lot quicker and a lot easier as well and probably a lot cheaper to be fair foreign [Music] setting guys I've planned that the chocolate box and the brake booster and this is the line for the vacuum station box that I'll probably run over there somewhere they're all planned in now so I've redone my brake booster pipe there and it comes all around down here is for my valve it's got the Boost battery going into the brake booster and then I've been to nearly manifold here that's the front end on guys it's only uh bolted on a little bit I wanted to check for clearance boost pipes and stuff and also for the fan around the throttle body a lot of the mark four people I think have clearance issues but there's plenty of space between the throttle body and a fan there to worry about that but yeah everything's on there brand new condenser cleaned out the radiator anyway back together just made a quick bracket for my vacuum station here this vacuum station allows me to run loads of vacuum ports from one vacuum Source in the inlet manifold so I won one source to it and then I'll run all my vacuum lines from it it's really handy bit of kit [Music] so anyone who's ever done an R32 turbo build would come across the clearance on the top radiator hose against the throttle body here I'm shortening the length of the bolt hole um so that I can create clearance to the top radiator hose you'll see in just a second how much clearer this actually gives um and there's no adverse side effects either [Music] and would you look at that clearance it's a little bit tight on there but it's actually not hitting anywhere now [Music] so absolutely perfect thank you very much to the guy on Facebook they're recommended I do this one of the most daunting parts of this was welding two O2 sensor bugs into the exhaust manifold this was required by stealth racing in order to map the car you know they wanted to know the air fuel ratio coming directly out of the exhaust so I had to weld these on there welding anything to cast iron is tricky because it can crack easily [Music] so for me this was probably one of the hardest parts of the job well not hardest but daunting parts of the job here I'm doing the bearings the Piston bearings it was daunting because one I get to see what the original bearings are like and I could unearth a an issue where I need to completely strip the engine down and and rebuild it as long as it fits in there nicely in in the uh bearing system that groove it should be okay I basically replacing the wad bearings here with glyco bearings which are an OE equivalent I'm using a plastic age to measure the Gap the clearance tolerances and I'm using ARP what bolts to put everything back together with it all went well in the end but it was definitely a nerve-wracking time every cap I lifted that could have been an issue that meant I needed to completely strip the engine apart which was definitely something I did not want at this point [Music] thank you foreign [Music] foreign [Music] [Music] foreign around the edge here and drill the port for the oil return from the Turbo get this back together [Music] so hopefully you can see on there there's a dirty line where the oil doesn't get to so this sits just above the dirty line so there'll be free flowering oil [Music] thank you [Music] there we go guys all right ready to go back home there's the drain ready to go back home so that's the sub back on now guys it's just the uh reverse of the removal got my 10 AM line there and plenty of clearance here on the drive shaft because we're on stands now so that's as low as the shaft will ever be we've got plenty of clearance there so yeah that's that little dad rod bearings and something done so here's the bearings closer up as you can see absolute minimal [Music] surface wear so I would say that that's a healthy engine so I didn't actually get any recordings of making the exhaust downpipe I didn't enjoy making it it was my first time TIG welding and some of the welds didn't look great and also struggled with it so I didn't actually film most of it you can see here how the exhaust is made and how it all goes together and the bends I did as well so hopefully that should give you enough reference around what you should need to do to make this exhaust fit foreign [Music] s get to go to the car for the final time there's no mocking purposes now it's just belt everything on Bolt the exhaust manifold on Big Turbo all the lines the Lambert of sensors Etc and just getting everything in preparation for the first start [Music] foreign [Music] so just preparing everything and doing a mental checklist of all the stuff that I need to make sure that the first start goes successful please foreign [Music] [Music] [Music] foreign [Music] foreign [Music] higher than the original crash bar and then I'll just welding it on there I really wish I had a MIG welder for this the tick really wasn't ideal but as you can see I got some nice welds on there in the end and uh yeah it's definitely not going anywhere yeah I'm about to fade away cause every time I wake up I feel like it's Monday something's going wrong with all the chemicals I did my brain all of a sudden I don't look at anything the same way gotta build up of my thoughts sitting in an ashtray I'm sorry that I'm so inconvenient okay just let me be me and I'll stay out of your way I could see the way you look at me I'm such a disgrace I never really asked to be brought into this place you wanna love me well then baby have a taste all the highs so it looks like I'm gonna have to bit that I started trimming I have to get rid of it because it's just hitting on everything basically so I have to get rid of that let's look at the intercooler [Music] yeah so I do apologize guys I didn't get the footage that I really wanted for the exhaust and the screamer pipe I found it very frustrating to do this work and so I didn't get the footage that I you know that you guys deserve so I do apologize about that but I'll actually probably end up remaking down pipe so and I make up to you guys and record it properly when I do that thank you [Music] [Music] [Music] the next big challenge for me was creating this four inch intake oriented technique to have various bits welded to it so for me that was particularly challenging uh this still isn't 100 right on the car um I'm still gonna need to probably do a redo this one and for anyone watching I hope you guys can pick up that I actually welded the math bung the wrong way round I actually welded it back to front so if you're watching this make sure you get yours the right way look at your map sensor and look at the direction it's going and weld it inappropriately I thought I had done this but but clearly I didn't pay attention to it when I actually came to weld it so make sure you guys do it it makes a big difference thank you [Music] I know you told your friend you're not okay [Music] but I've known you too long it hurts to watch your blue eyes Fade to cry [Music] even when you feel low you can still go even when you feel slow you can still go even when there's no hope you can still go I never answered a no man I still go go go go go go go go go go go go go go go go go go go go go [Music] [Music] [Music] thank you so guys so my Turbo doesn't have a pressure port on it I like to use these this sort of nipple thing but clamps either side of silicon hose it's got some O-rings in there as well to keep it sealed so that's coming it's gonna sit so about there but probably most likely towards the back if I can fit it it's gonna be a tight squeeze and then that Port there is going to go to the wastegate bottom port and then when I planted the Boost controller in and I have the Boost controller set up here and that's going to go from there to the Boost controller from the Boost controller to the bottom port on the wastegate controllers [Music] I've just got back out of stealth racing um Vince has put a base map on the ECU so that means that I can drive the car around do some running in find any issues fixing them and I hope we won't have any teaming issues so I'm excited let's get back home let's get it in the car and let's get out on the road [Music] [Music] we're out in it guys so on the first drive and uh the screamer pipe shipped me out when I first when it first went on uh I thought a boost pipe had popped up or something I've never been in a car with a screaming pipe in before but yeah that was an experience so like I said I made it here I'm only a couple of miles down the road I've only done about four miles in it idle's lovely drives nice comes under boost this is how it's running we've got an absolute lovely just like it was stopped yeah the clicking you can hear is actually the injectors it's pretty noisy to be fair I didn't think they'd be that noisy but maybe standard ones are that noisy but it's covered with a you know plastic Inlet manifold the base map from stealth is cracking like always it's a lot quieter than uh and it is standard really well then it was non-turbo charge crap about a decade guys I'm cruising about 70 miles an hour and I can hear myself think I'm not sure whether I like it or not but the exhaust is pretty quiet obviously it's on the screen but pipe so that kind of makes up for it but coming from my d-cat n a engine sound very quiet and you know very very good for commuting there's no drone or anything unless you guys can probably tell on camera but yeah very quiet yeah so all I'm doing here is trying to fit the turbo blanket this one was from Laureate Motors and they actually turned out to be really crap quality so don't get it from Laurie Motors at all and do yourself a favor and get a decent quality one let's burn up within 500 miles it was like a charred blanket at the end so definitely get yourself a decent quality one [Music] so guys here's our catch can here I have already had it on the car just as a temporary measure I'll take it wake up today's gonna be a good day wake up today's gonna be a good day wake up today's gonna be a good day today's [Music] [Music] this afternoon [Music] [Music] [Music] and that's gonna fit like this so most modern cars you actually root the crankcase ventilation back into the into the inlet so what I'm doing here is I'm welding the nipple so the ventilation come from the head to the catch can and into the intake man said meditate it's pretty cool that I'm alive and that better days I could walk see here I should celebrate think I could change my mind maybe Elevate living life every day [Music] between a rock and a hard place do I work hard or live in my pace you're only young one yeah that's all great but I also wanna feature where I'm okay living life is doing lots of cocaine hey guys probably the ugliest World you've ever seen on YouTube it's that tight it should work I think it's different for everyone some of us need work others need fun so my boss needs purpose to overcome but try to do what you love when it said it done cause there's so many differences in each of us trust your gut they could show you what you want living life every day are some better days [Music] for me it'll be half an hour for you it will be and we're back the house is done good let's get it fitted [Music] and I pray I believe in the better days so we've got from our an10 here into the oil box and then down into the intake down there so guys this boost schedule working breathing vacuum at the moment and then to reboost when you get into the booth yeah it's all working guys I just took my old filter off my inline oil filter for the turbo so that I could slip the insulation on and look at the core in there definitely doing this job just checking every now and then and it should be fine one of the last things to do and probably the most important is the heat shielding for all the rubber lines the am lines Etc all around the turbo and the engine bay area we really want to get the heat away from this these pipes and the coolant and the oil Etc so you don't want any radiant heat to be heating anything up so here I've got some fiberglass sleething that I'm going to put over all the pipes just to protect them from all the heat that the turbo makes especially now that I'm not running a turbo blank [Music] [Music] so the last thing I had to make was a heat shield to go over the manifold itself I used the OE heat shield and just cut it to size and shape and gave a little Bend to go around the spa turbo manifold this this helps massively to keep the heat down um there's better options and I will probably redo this anyway out of some sort of fiberglass heat shielding but it was all I had at the time and and it does work pretty well to be fair so it was definitely a worthwhile thing to do and here I'm just tired doing everything I'm getting all ready for the final time so I can go out and get mapped to stealth racing [Music] [Music] I know you told your friend you're not okay and tell me what's wrong and why you've never said you felt that way

Channel: Octane Fever

Views: 19,024

Keywords: GOLF, GOLFMK5, GOLFTURBO, TURBO, r32 golf, vwgolf, golf r32, golf r32 turbo, r32 turbo, r32, vw mechanic, vr6, vr6t, mk4 r32, vr6 engine, vr6 explained, mk4 golf, mk5 R32, best VW golf, 4 motion, how to buy a used car, used car buying guide, mk5 problems, mk5 r32 issues, build an engine, how to build engines, is it hard to build engines, r32 engien, vr6 engine guide, turbo R32 engine, turbo VR6, octanefever, octane fever, the octane fever, mk5 r32

Id: 47hFZzAue3A

Length: 42min 31sec (2551 seconds)

Published: Thu Dec 15 2022