01/06/2026
Unbelievable π²
The last time Millie's Mk5 GTI left DT it was on the back of a trailer, which is a shame as it drove 3 hours to get here.
She had done a load of work to her car with the bulk of it being the K04 conversion. It came to us for Carbon cleaning / injector servicing and then tuning.
Prior to any carbon clean we like to do some diagnosis for the thermostat as its the perfect time to swap it out if it has failed open. This consists of a steady drive on a nearby bypass with logging on. During this drive the car suffered a sudden loss of power and came to a halt.
It wasnt dramatic and initially wasnt even entirely obvious as to what was up. The pool of oil underneath the car confirmed the worst though. It had just thrown a rod out the front of the block!
I mean... how do you explain that to the customer? Luckily again for us we log this drive, which not only showed what had happened, but also how it happened. Its pretty unbelievable, but this happened with no load, no excessive boost spike, no real reason.
Whilst Millie was at first a bit upset, she took the bad news like a champ. She had her own apprehension about the engine work as she did it herself, but I honestly dont think there was a problem there considering the car had just drove for hours to get here.
It is just one of those things that is sadly clouded by the timing of when it happened. And if it didnt happen on the road, it would have absolutely spat its dummy out on the dyno.
Undeterred by the failure, Millie took the car back home and before pulling up had secured a replacement CDL engine. The new engine was installed and running before we even had time to get over it. Believe it or not these failures lie heavy with us too.
The car then returned back to us, and we carried out the carbon clean on this engine. She had a less than perfect injector (not connected to the previous failure) so we supplied a new injector direct from TPS.
Unbelievable happening no.2 was that when tuning the car we had a terrible misfire condition which was traced back to the new injector that we supplied and fitted! So off came the manifold, and the injector was swapped out again!
This time the tuning went great with no misfires and the car responded perfect! The DSG got the TVS Stage 3 attention before being pushed with Nick dialling in the ECU calibration. The plan was always going to be to take the car on track so a nice linear throttle response, with full control of the boost and load. It ended up a bit of an animal and gobbled up the road great, just like a Mk5 K04 conversion should!
This job was challenging!
Not only for the way that the car fought us. Or how it took way more time due to the failures. Or even how in times like this its important to double check and have due diligence in your work and procedures. Or that it involved having the difficult conversation with the customer.
Luckily I have no hair to lose though, so you just have to crack on, have confidence in your approach to the work, tried and tested solutions and above all else have some humility. Yes you're dealing with someone's car, but its also their hopes and dreams. And when it goes wrong, its how you deal with it thats important.
And in the end Millie appreciated the effort on our end, as she boosted all the way home! Cheers for remaining positive and keeping rhe faith!
Now... have you known of anything as crazy as this...? We'd love to know.
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