cj1

Hi, I've recently acquired a Lupo GTI and in contrast to the rally car, this should provide a nice little project to restore a car that's in need of some good old TLC. 2004 6 Speed, Black 112k miles Sunroof So every panel is scratched and there are two large scuffs on the OSR and NSF. Interior is very clean, but the outside not so. I've made some minor cosmetic changes already, and discovering a few little issues with the car along the way. I shall use this first post as an active list to update with issues and modifications. I would like to keep the car as standard as possible along the way, but keeping an open mind. Modifications LED rear number plate lights LED Sidelights - match the factory Xenon's Red GTI Grille Piping Issues Car does not hold temperature or warm up, sits around 70 degrees - Now fixed with a new thermostat Steering doesnt feel right and occasional clunk feeling. Looks like split suspension arm bushes. Wipers split Engine cover split Heater controls are very, very hard to change from Window/Feet side to body side. Heater blower seems to make a squealing noise on speeds 1&2. Heavy kerbing to all four wheels Clutch Judder when moving at low speed, and a grinding noise in neutral. Suspect clutch release bearing. Ultimately the plan is to use this in place of the Arteon which I'm getting rid of in March. So got plenty of time to sort these issues out. I'll keep here updated, and pictures to follow Work Completed New Clutch & release bearing new suspension arms New ARB drop links New Ball Joints N/S Outer CV Boot replaced New track rod ends 4 wheel alignment New thermostat Replacement 6 speed gearbox cambelt & water pump changed

In fact, from memory, the polo GTI AVY mounts to an 085 box I think? Which I want to avoid using in any future build if possible. Would also like to retain the bolt in flanges on the driveshaft, does the 02T use this? Funnily enough I've just bought a Lupo GTI so I may be underneath later on checking this out!

You may be useful to ask this actually. Ultimately, this is a very high level plan, but I'm thinking a AVY bottom end with the AFH head in some configuration. This should allow a number of things: 02T Gearbox (Do any of the other 02 Boxes fit? ) , which means I can get a proper gear kit for it, and is more reliable, etc etc. Are the Polo & Lupo GTI AVY Bottom ends the same? I notice quaife only do gear kits for the 02M/02Q.... I need to properly research all of the above before any decision is made

Had a relatively quiet year competing. But considering moving up to the 1600cc class and building a new engine. Need to get new belts over winter as mine are now out of date for competition, and got a few other little upgrades planned. More to follow.

Wind deflectors? And how bad is the dent on the bonnet?

Can't beat washing up liquid for removing grime and grease.

Any that you make fit.

Back end still locks up on mine with the bias valve wound all the way off. You get used to it.

Yes, however OP only mentioned draining all coolant, not refilling too

Sorry if I've completely missed the point here. But has the sensor itself been tested? It's one of the easiest things to change, and I too find it hard to believe that water has gotten into the ECU and the only contact to be affected out of the many, many contacts inside is just the throttle pot one....

Remove the thermostat and let it run for a minute or so from cold, with the thermostat cover plate removed..

Welcome! A hairdryer would be fine for removing the side strips. Mine peeled off very easily, but the remainder I removed by using a bit of heat and petrol (Although I'm sure tar & glue remover would work just fine!). Provided you clean it up properly, there won't be much of a colour difference A few mods I've seen (And done back when I had my first Lupo!) Colour coded door handles (I may have some silver ones sitting about actually) De-wiper rear Change of colour to interior dashboard panels Cup holder - You'll definitely soon want one if it doesn't already! Mudflaps (Some on facebook atm for around £20 IIRC) LED Number Plate Lights LED Interior Light Replace 12v cigarette lighter port with twin USB socket. GTI Instrument Cluster & Binnacle GTI Seatbelts (Good luck) GTI Steering Wheel Look forward to seeing the updates!

Car back, fresh paint. Slowly coming together now 😎

The usual upgrade is to sport/tdi/gti front hubs/uprights which allows the fitment of the 256mm brakes. Not sure if anything is particularly different that would stop this on the 3L though.

Looking good! And thanks for the handy tips regarding the top mounts!

Well, some good news I think! Ive taken the car to someone to have a look at, need to be ready for the start of May so makes life much easier. Compression on all four cylinders is fine, no issues. They think it’s just that the spark plugs were really bad. Potentially unburnt fuel or something then? Given compression is good on all 4 I can’t see it being actual oil getting in. Perhaps I panicked a bit?

Well, some good news I think! Ive taken the car to someone to have a look at, need to be ready for the start of May so makes life much easier. Compression on all four cylinders is fine, no issues. They think it’s just that the spark plugs were really bad. Potentially unburnt fuel or something then? Given compression is good on all 4 I can’t see it being actual oil getting in. Perhaps I panicked a bit?

I guess in summary I’ve changed from what was a 3.7:1 final drive to a 4.27:1, using only standard 085 box parts. built it using gears from two different gearbox codes. 2nd goes to about 53, 3rd 73, 4th 86, and I’m guessing 5th will be about 100ish. 3rd used to be good for about 110. Hoping this difference shows in the stage times. Acceleration is so much better now!

In that scenario that would just be the gasket I think? It's been that long since it's been in bits anyway I couldn't remember where the feeds where to be honest. Yeah I saw your write up on them, I've got some longer bolts so will be sure to put them in as soon as they arrive. I'll post ratios soon.

Sorry would be combustion chamber I guess. removed plug and oil was dripping out of it

Well. I took the car for a drive and wow. What a difference. The gearing is miles better! but that’s where the positive ends. Thought I’d do the spark plugs. Cylinder 1 is full of oil 😰😭

Well. I took the car for a drive and wow. What a difference. The gearing is miles better! but that’s where the positive ends. Thought I’d do the spark plugs. Cylinder 1 is full of oil 😰😭

Yes exactly, it snapped the inner cv on the passenger side. I ideally need to be adding some lock stops to restrict how much lock I can get, but for now I'll just remember to be careful! Ahh that makes me feel better. It was running perfectly before doing any of this work, so nothing can have suddenly changed, I suspect it will go away. It did start dying down after a while.

So I'm mindful that I haven't really been keeping on top of this, so I'll try and summarise recent changes I've made over the last year or so along with what I've got to do. I fitted a gearbox with a LSD.. Had a few issues with driveshafts but only one true "failure" - as mentioned above. The others have been driver error, giving it full throttle on full lock. Can't get away with that anymore! The above mentioned gearbox was one of the 085 boxes with a 3.7:1 F/D ratio. The grip difference was huge, but so was the difference in the gearing. It was awful. We never got out of 3rd, even going down the straight at cadwell park at 98mph with plenty left to go. Following this event, gearbox was removed from the car for a rebuild with different ratios. Happy to say after 3-400 competition miles there was no wear at all on the diff or the synchros etc. so didn't replace any of these. Rebuilt gearbox is now back in and ready to test In terms of what's next. Fit another handheld extinguisher Roll rear arches properly. Get both sides & front bumper painted. New n/s wing. Service - Oil, spark plugs, fuel filter, wash air filter etc. A general overall clean New doorcards to go in - neaten the inside up a bit more MOT (Being done next week) Fit Silver Project Top mounts Fabricate solid engine & gearbox mounts. Overall the car has been really reliable with only one retirement due to my error with the coolant cap, so I'm hoping to keep it that way. Potentially look at building a new engine this year, but for now it's fun & reliable so why change a good thing. However, I started the car up on stands the other night to run through all the gears and check they engage as they should. And they did. But I noticed a bit of smoke in the garage. Seems the cause of this is from the crankcase breather. In my case this doesn't go back into the intake, just vented into a bottle. But the smoke is unusual and I haven't noticed this before. However the car has been sat for just over 3 months with the front end up in the air without being ran so I'm wondering if it's just because of that. I'll take it for a proper drive soon and see what happens, hopefully it clears up. If not I suspect the rings probably need changing. But we will see. The smoke isn't particularly thick or of any distinct white/blue colour mind...

Now you come to mention it, I do remember seeing this amendment.. My bad! Although good to be sure