VW Golf MK2 - Replacing Handbrake Cable on Car with Rear Discs

When doing various bits of work on my Golf MK2 I'd spotted that the handbrake cable on one side was corroded and looking in need of replacement. While collecting the brake discs and pads from Eurocarparts I also picked up a new handbrake cable to fit.

The old cable was still functioning but may well have been an MOT fail soon or stopped working once the rust had affected the cable inside.

The cable was easy to replace. With the vehicle jacked up and the rear wheel removed the retainer could be unclipped. The cable inside the car can then be unbolted from the handbrake lever and fed back through. I found it easier to remove the drivers seat to give better access to the handbrake and the new cable being pushed through.



Golf MK2 Replacing Handbrake Cable - Old vs New

 

 

Golf MK2 Replacing Handbrake Cable

 

Golf MK2 Replacing Handbrake Cable

Golf MK2 GTi 16V New Brakes - Fitting New Discs and Pads

One of the jobs I've been wanting to do since getting the car has been to replace the brakes all round with new discs and pads. Having paid a visit to the friendly local branch of EuroCarParts this week I managed to get supplies of all the required parts ready to do.

The front brake discs were not in too bad condition but did have some scoring and rust. I wanted to replace the discs and pads all round and the rear ones were in poor condition. The rear brake shields were also very badly rusted so I obtained new ones from the VW main dealer to tidy the appearance up - although only me and the MOT tester will actually see them!

The front brake discs on a VW Golf 16V are 256mm, the smaller 239mm ones are for the standard models in the range. With the new brakes, new suspension, new springs and replacement bolts fitted this part of the car is now looking very much better and should give good performance for some time to come.

Old brake disc showing wear and rust

Golf MK2 GTi 16V New Brakes - Fitting New Discs and Pads

Cleaning new brake discs before fitting to the Golf GTI

New brake disc fitted to Golf 16V

New brake disc fitted to Golf 16V

Once you've fitted the new pads and discs make sure you check the level of the brake fluid reservoir. With the additional depth of the new pads it can force more brake fluid back out of the system into the reservoir container.

I had to remove around 50ml of brake fluid from my VW Golf after changing the pads as the reservoir was overfilled once the piston had been pushed back on the calipers.

Replacement Golf Idle Control Relay 443 907 393N

My VW Golf MK2 16V isn't idling very smoothly when initially started so one item suggested to investigate was the Idle Control Relay part number 443 907 393N.

 

This just arrived from an Ebay seller for £20, they are no longer available from VW but before being discontinued were sold for £616!

 

Idle Control Relay 443 907 393N

One of the jobs next week will be to fit this and see if it improves the idle when cold on my 16V Golf GTI.

Cambelt Fitting Golf GTI 16V

After checking all the paperwork for my 1989 VW Golf 16V GTI it appears the cambelt was last changed in 2009 so a replacement is now overdue.

For such important parts I much prefer to buy direct from the VW Main dealer so I know the parts will both fit and last as long as possible. VW part number for he Cambelt on VW Golf Mk2 1.8 16V GTI is 027-109-119C

VW part number for he Cambelt on VW Golf Mk2 1.8 16V GTI is 027-109-119C

Cambelt on VW Golf Mk2 1.8 16V GTI is 027-109-119C

Cambelt tensioner on VW Golf Mk2 1.8 16V GTI

VW Main Dealer Parts for Old Volkswagen Cars - Finding Part Number Codes

Since getting my MK2 VW Golf in early 2014 I feel I've become something of an expert in VW part numbers and seem to spend a huge amount of time at my local VW main dealers or on the phone to them.

I know main dealers are often called "main stealers" for the high prices they charge for servicing and new cars but I've been both surprised and impressed by the availability of parts for a car that is now over 25 years old, the reasonable prices and with the helpfulness of the main dealers parts department.

Some obscure parts have been only a few pence and even the most expensive was around £60 so being able to keep stock of spare parts for cars so old is quite impressive.

I've found online parts catalogues, been able to examine components with a magnifying glass to find out the part number stamped on and search the power of Google to locate the name for parts I need. Until my MK2 I had no idea that parts were labelled in such a way so it has been a fantastic learning curve for me.

To be able to find a part,locate the part number and source a replacement has been a really rewarding challenge and has made bringing my MK2 Golf 16V back to original spec even more interesting.

VW Main Dealer Parts for Old Volkswagen Cars - Finding Part Number Codes

Even on a part as small as the hall sender plug above it is possible to find the part number code but obviously easier with a large part such as the rain deflector below.

Finding Part number for Volkswagen spares

Terminals for Hall Sender Plug on VW Golf MK2 16V

One of the wires to the Hall Sender on my VW Golf MK2 broke last year and I've been running it using a terminal block since. I want to get the new plug fitted with new terminals so there weren't multiple joins in the wires. The new hall sensor plug was bought from VW, part number 443 906 236

I found this company selling the terminals and plan on using them to replace the terminal block with direct wiring.

http://www.vehicle-wiring-products.eu/product.php/987/female-1-5mm

Hall Sender Plug on VW Golf MK2 16V

Terminal removal tool for VW & Audi terminal plugs

Terminals for Hall Sender Plug on VW Golf MK2 16V

Missing VW Golf Cambelt Cover - Locating a Replacement for Part number V027 109 123B

One of the jobs outstanding when I bought my 1989 VW Golf GTI was to fit a new cambelt cover. The bottom half of the cambelt cover was present but the top half was missing.

VW Golf 16V GTi Cambelt cover missing

VW Golf MK2 16V GTi Engine with Cambelt cover missing

Initially I was unable to source one but have now found a really useful site listing all VW part numbers
http://vagfans.info/EN/volkswagen/RDW/GO/Golf/1989/92/R/121/22010/cooler-for-coolant-flange#11

Using this I found the cambelt cover part number as V027 109 123B and have managed to pick one up from my local VW main dealer. The cost was only £22.60 ex VAT which from a main dealer seemed pretty reasonable and I didn't need to cover any postage as I could collect.

Missing VW Golf Upper Cambelt Cover - Part number V027 109 123B 

Missing VW Golf Cambelt Cover - Part number V027 109 123B 

Golf Mk2 GTI Front Grille Fitting

One of the jobs I needed to do when I got my Golf was to secure the front grille correctly. When I bought it the grille was attached with cable ties so I wanted to get the proper fitting. These are some shots of the grille before fixing it.