grungeisdead

Spotted you going past the police station coming up to the roundabout where the retail park is, was in my bosses passat. pretty sure it was lowered slightly with ronal-esque wheels on it, girl driver, only got a glimpse mind but woop for the loops

Thanks to all those who have done it before, and left bits of info scattered around and helped me out personally during the process, in particular these guys, Pinguspolo, Mitchell, Mikeymk, Skodaboy, Jez. What you need Essentials Headbolt - 036103384B ( x 10 - for 1 cylinder head) Polo GTI Headgasket 036103383Q Metal Inlet Manifold Gasket 036129717G AFH Cambelt 036109119H AFH Tensioner 036109243J AFH Relay Roller - 036109244 Water Pump - 036121005D/036121005MX If Required Polo GTI/AFH Sump Gasket Sealant - D764004A2 AFH Cylinder Head Cover Gasket - 036103483 D & 036103483 G ARC/AVY Piston Ring Set 036198151C ( x 4 - 1 set per piston) - If required ARC/AVY Crankshaft Bearing Set 036198491 Alternator belt HB680G (Halfords) - For Mk1-3 Conversions using the Mk4 Alternator Alternative Suppliers GSF 132VG0180 TIMING BELT IDLER PULLEY PO 1.4 16V 95> 21.95 170VG0140 WATER PUMP PO 1.4 16V AFH Eng. 95> 26.75 Considerations Headbolts 6n 1.0 AER & Non AVY GTI lumps have the correct length headbolts 6n Polo 1 Litre 036103384B bolt, with multi-spilne socket head M9X1,25X138 / AER,ALL Lupo GTI 036103384B bolt, with multi-spilne socket head M9X1,25X138 / AHW,AKQ,APE, AUA,BBY,AFK, ANM,AQQ,AUB Polo GTI 036103384E bolt, with multi-spilne socket head M9X1,25X97 / AVY The correct part from GSF is 01163 CYLINDER HEAD BOLT PO 1.4 AFK/AHW/APE/AUA/AUB Engines 99> & PO 1.0 AER Engine 96>99 £2.00 each and you need 10. Relay roller part number 036109244 the guys made me a bar threaded to 10mm at one end to fit into the block and 8mm to fit through the sleeve of the roller, it was impossible to drill through for guys with thousands of pounds worth of machinery so dont bother trying it at home, I'm glad i didnt bother! see below i can confirm this, i've tried to drill one out in a big badass lathe, clamped the sleeve in the chuck and using the tailstock chuck/drill and even with cobalt drills and plenty of cutting oil it barely even tickles the surface, it's because the sleeve has been nitride hardened which is the same way gudgeon pins are done, if you could drill through the surface layer it would probably be quite soft underneath.. tbh i can't believe they would go to the effort of nitriding a component like this... i think i'm going to have to make up a threaded bar like the op with M10 one end and M8 the other end... or the other option i'e thought about it drilling and tapping the hole in the block and putting an m8 insert in there Headgasket Polo GTI Headgasket 036103383Q Fuelling & Management I leave that up to you, but there are carbs, independant throttle bodies, or the standard EFI. I cover fitting bike carbs to this setup, albeit for a 1.4 16v here. Some reference threads 1.4 16v AFH mit 1.6 16v Lupo GTI Bottom End, PikeyTech® Conversion underway Mk1-3 Polo 1.4 16v FAQ + Conversion Guide, & General AFH on Bike Carb Guide. Fitting bike carbs onto a mk3, Parts needed some pictures Enjoy! PS. I take NO account for mis-information, accept no liability for any damage caused to your engine, yourself, or any third-party based on anything in this guide. As always, it is ENTIRELY AT YOUR OWN RISK. ** ALL USER GUIDES ARE INTELLECTUAL PROPERTY OF THE AUTHOR, NOT CLUB LUPO **

pics are up on the facebook page, as well as in the meets section of edition38. they arent mint so thanks to dan and chris for taking them, was good meeting some new faces, and catching up with old. hopefully see some of you's at vw action and ill post up a link to the next MU meet when we've finalised the date, might be nice to have a convoy/drive up to the peaks

facebook group here so you can keep up to date with the latest meets/events http://www.facebook.com/group.php?gid=126381380705741&ref=ts or search for manc:union peace + love saf

finally found all my hub mounting bolts so the front brakes are on - lucas 54 calipers, ferodo ds3000 pads and ebc discs 200mm rear drums and v dutty powdercoated rear axle, still awaiting my rear handbrake cable, when thats here i can get the bearings fitted. gotta order me wheel cylinder and brake lines tomo, but still desperatly need a clevis pin pedal pushrod thing for the master cylinder and the MC spacer. should also get hold of an uprated suspension kit for the rear as these shocks are truely pwned but should be mot'able for time being grille and lights fitted, bonnet just rested in place, got another black one but need to get the vent holes are the rear welded up trial fitted top fill rad, unfortunatly its gonna require some slam panel butchery, i think rather than just messily cut it out, i've got various hole saws, so ill make a circular cut out big enough to pull the cap out from and notch the inner part of the panel so i can get some grippy action around das cap. id rather retain as much of the original slam in place for fear or it collapsing! note the grille cut out in this pic, im going drill the panel behind it, and fit an air scoop as fitted on GT's iirc and feed that over the carbs, eventually getting round to sorting out a plenum chamber for them random pics then spent the rest of the time sorting out bits in the unit, getting rid of pap ill never need, and boxing up the rest ready for an ebay flex. heres what i uncovered from the house alone, its all gonna go on ebay at 99p starts when i get round to putting them up (next week or two)but if anyone wants owt gimme a shout Mk1 Golf GTI Magnecor KV65 Competition Leads Red with 2 Cable tidys GTI TSR Drilled Airbox GTI K&N Panel Filter GTI Warm Up Regulator 438 130 073 GTI Cam Pulley - 056 109 111A GTI Lower Crank Alternator Pulley GTI Water Pump + Near new thermostat+housing GTI Near new Bosch Starter Motor 055 911 023B GTI Drivers Engine Mount - Rubber needs replacing GTI Rear Gearbox Mount + Rubber GTI New Downpipe Gasket GTI Complete Series 1 1600 Metering Head/Injectors/All Braided Lines/Fuel Filter GTI Semi Polished Alternator GTI Oil Cooler / Hoses / Mounting Brackets GTI Series 1 Contact Breaker Dizzy - Near New Condensor & Contact Breaker 049 905 205E GTI Series 1 Parcel Shelf GTI Complete Series 1 1600 Head / Cam / Water Housing / Inlet Manifold / Throttle Body GTI Short Driveshaft - Good condition, relatively new inner CV Bosch Starter motor 055 911 023L Gearbox Selector Shaft New Tensioner Stud New Linkage Rod Bush Tintop 3Door Green Tint Glass Front Passenger/ Rear Drivers / Rear Windscreen Tintop 3Door Clear Glass Rear Passenger Polo Mk1-3 Lower Strut Brace - Adjustable but ONLY for cars up to -40mm. Mk2 Polo Coupe S Contact Breaker Dizzy - Near New Condensor & Contact Breaker 023 191 009 / 052 905 205 Mk2 Polo Coupe S Airbox/Filter/Elbow Mk2 Polo Coupe S Exhaust Flexi Section Mk2 Polo Coupe S Metal Cambelt Cover Mk2 Polo Powdercoated Water Housing & Thermostat Housing 052 121 117 / 052 121 171C Mk3 lower steering cowling cover 171 953 516B Mk4 Polo 1.4 16v Power Steering Pump Pulley Mk4 Polo 1.4 16v Power Steering Pump Pulley + Pulley Mk4 Polo 1.4 16v Crankshaft Cambelt Sprocket Mk4 Polo 1.4 16v - Plastic Dizzy Cover & Lead Tidy 036 103 565A Mk4 Polo 1.4 16v Power Steering Pump Pulley Mk5 Polo GTI 1.6 16v Inlet Manifold Mk5 Polo GTI 1.6 16v Cylinder Head Mk5 Polo GTI 1.6 16v Red Rocker Cover / Cams / Pulleys Mk5 Polo GTI 1.6 16v Standard 4 Branch Manifold Mk5 Polo GTI 1.6 16v Decat Downpipe Mk5 Polo GTI 1.6 16v Flywheel Mk5 Polo GTI 1.6 16v Engine Wiring Harness Mk5 Polo GTI 1.6 16v HT Leads Red x 4 Lupo Lupo GTI 1.6 16v Standard 4 Branch Manifold Lupo GTI 1.6 16v Decat Downpipe Lupo GTI 1.6 16v Hydraulic Clutch Release Cylinder 600 721 261A Lupo GTI 1.6 16v Engine Wiring Harness Others VW Cable Change Conversion for Hydraulic Clutch Gearboxes Coil used in Emerald Setup - 089 04B 00104 - Leads from top left, clockwise are 14,32,27,41 Audi 3 Pod 52mm Guage Facia - 812 863 321C 2.5" NOS Veglia Borletti 8 Bar Oil Pressure Guage BMW Smaller, Lighter Power Steering Pump Pulley to fit Mk4 Polo 1.4 16v - 1715769 52mm VDO 150 degree Oil Pressure Guage 12" Slimline Fan Opel Manta GTE Tartan Recaros 320mm Aftermarket Steering Wheel Slimline Ali Rad 12"H 1.75"D 20.5"L 23.5" between mounting lugs saturday well productive day was had today, we put nays mk3 polo back together after he took apart to change the headgasket and a few other bits, and i got to pilpher some much needed bits for the mk1, muchos kudos to nay anyway bits done on the mk1 * rear wheel cylinders fitted both sides * rear shoes fitted both sides * got a nos handbrake cable but its such a random design, need to fathom it then i can fit it tomorrow * new clevis pin fitted on the pedal box, all circlips in place and nos master cylinder fitted * interior loom fitted * dash fitted * clocks/speedo cable fitted * earthes fitted. * made cut out for top fill rad * mounted front number plate * mounted both front seats * fitted washers and locknuts for wiper mech and fitted wiper arms (well one, as the other has gone awol and they are mk1 polo specific!) * bonnet catch and release lever fitted * fitted new door seals and the new oem shoes to keep with the lupo theme when i get hold of some tyres, if anyones got any 175/50 185/50 195/45 14 inch rubber lying around gimme a shout picked up a new water pump today and getting at gt 5 speed box from dubmania tomo, so the engine should be in the car one evening next week, proper buzzing list for tomo horn + hornpush rear handbrake cable full brakes lines + bleeding relay - lights harnesses ignition wiring loom/coil/tca power distribution block rear number plate light and heated rear windscreen list for week rear beam bushes water pump / cambelt oil pickup/sump flywheel/clutch clutch release bearing/gearbox crane bonnet/bonnet stay parts list clutch release bearing gearshift base afh starter motor thats enough to jog my memory for tomorrow couple of crap pics sunday fitted full new solid line and flexis, solid lines from rear are 15cm and 40cm too short so will get some extra lines made up in the week fitted brake pedal return spring wired up coil and ignition loom working rear electrics, unfortunatly told the welder to weld up the hole for the numberplate light wiring DOH! so will drill that out fiited water pump / cambelt and timed up engine, will refit sump tomorrow and then the lump is ready to go to the unit. need to pick up das GT box from hoppys in the week and then chuck the engine in there woop

got 28 days till the unit gets turned into a helicopter pad =/ so thats my deadline to get it running and out of there, if anyone wants to come grab some free/cheap parts to save them from mr scrapman, pop over wouldnt mind a helping hand too =D anyway engine loom found in the unit, main earths connected and fusebox screw in place, battery fitted. badly need the nuts and grommets for the wiper mechanism, anyone got any kicking about 6,7,8 wiper locknut and washers and any plastic or rubber gromets pics of seat mounted, pedal box and steering column fitted. although i broke the clevis pin, so if anyone has one? 6a and 6b clevis pin 12 cirlcip engines internals cleaned, sprayed down, drained and wd40'd up, sump bolted on to stop dirt getting in, but not cleaned up the mating surfaces or gasket pasted them up yet. just need a waterpump and i can get the tensioners fitted, head on and cambelt fitted. then i need to get hold of a 5 speed box, or just bolt ad's 4 speed in as a quick fix

94 on your lupo, only 76 iirc on mk1 golfs and mk1-3 polos (also mk1 jettas,roccos)

done today undersealed rear inner arches after welding undersealed welded engine bits sprayed and undersealed the bucket seat mounts removed old 180mm drums fitted 200mm back plates and stub axles fitted bearing races into new 200mm drums fitted handbrake lever and front part of handbrake cable fitted wiper mech - need the clips, nuts and grommets to attach the spindle bits tho if anyone can help ate donuts drank irn bru and got baked <3 tomo keys coupe s wheel get brake lines made up buy - 2 rear flexis, 1 wheel cylinder,handbrake cable circlip for brake/clutch pedal x 1 cirlip for throttle cable x 2 dremel rounded rear brake line fit rear drums, hb cable, brake lines fit front calipers/discs/flexis fit pedal box and pedals steering column UJ gear lever fit wiring loom studs for seats and fit

well after another sabbatical, work continues on the mk1 this weekend, some goodies to fit 200mm passat rear drums, back plates, stub axles and wheel cylinders, new vw shoes and bearings. 256mm ebc x-drilled grooved discs, lucas 54 calipers and ferrodo ds3000 pads and the new lump is nearly done, just need to get a water pump, gearbox and clutch kit and woop. its now an 1.6 16v sporting Shrick Fast Road cams. laaarvly. will get pics after this weekends frolics

you'd want uprated rods and pistons, they wont be cheap, and a diesel turbo wont be suitable. alot of effort for not alot of gain, far better starting off with a much better engine to start off with, but even with GTI internals or AFH items, the con-rods will stil be the weakest point and youll want forged items. look at some of the build threads for the charged, and turboe'd gti lumps on here and itll put you in a better position to understand what you will come across and what youll need. youll also be blowing alot of money on standalone engine management to get the best out of your setup. i'd say if your going for it, start with a gti engine from the off, or a polo gti bottom end (or internals swap into an afh block) and an AFH head, set of ITB's, standalone management and your laughing, scope for a charger too, if you go for uprated internals too

yep they have a throttle position sensor mate, not about next weekend, ill be all all types vw show. yep i have the avy head in the picture for top picture for sale, 120 quid, thats for the head with cams, rockers etc, no coilpack/leads/water housing assembly/inlet manifold or throttle body, but have most of those available seperatly, cheers saf

cable tb retro fitted to the loop gti for sale 50 quid

yep its just that, alot of people dont realise the extra expense of aftermarket management and mapping, and if you cant do it yourself, and pay someone else to do it, it can rack up into the thousands easily on garage bills alone. plus many people think itbs and bike carbs are similar and can be run in the same way, but they are both very very different. if i was going down the route of forced induction, id do it with a set of itbs, but obviously id be looking at minimum forged rods to replace the vw chocolate variety

didnt fit them myself mate, i bought them for the lupo gti lump planned to run on megasquirt, but building a hybrid lump now with an afh head so i can run on the standard late mk2 polo ignition setup and run carbs, saving me money however as you cant have a mappable ignition curve, so you lose some of your scalability. imo for proper tuning itbs are the way forward especially with newer engines, however im a pikey and love the cheap quick fast solutions and carbs are ideal to my needs. carbs will give a 100bhp AFH lump 25 extra ponies, so i would expect a well mapped ITB setup with respective suitable breathing mods out the exhaust could see 30-40 bhp bear in mind thats full of guesstimates with no proof, although the 125 out of the valver lump is proven on max croxs mk2 polo

i'd be wary of them, they have made various items in the past such as eaton conversion kits for g40's and the quality has been suspect at best. However the custom fabrication they did on the shell is top-notch and im very impressed. Can't fit any other box bar a lupo box to the lupo lump, and i would be using an 085 box (early polo mk1-3) which are far stronger than the mk4 polo onwards and lupo equivalents. i have given my daily driver 1.4 16v mk2 polo on bike carbs death since ive had it on the road, the clutch release bearing was dying when i put it in (despite being replaced only 2k before, but was a non-genuine part) so despite the noise when my clutch pedal isnt depressed, its still flying through all the gears, no crunching, no slipping, and still feels as tight as the day i put it in. plus i can pick up the boxes at 50 quid or less when/if it does blow up, wheras a lupo box will be considerably more expensive. not really bothered about keeping the block as a spare, i have too many engines anyway, however i fear the lupo crank may be different to the polo gti one, unless its simply a wider crankcase but the cranks are the same, i would check on vagcat but its fukenbroken