ObjectiveAway

Might be the gearbox bearings. If the noise gets significantly louder during engine braking, don’t keep doing it, then the gearbox is close to failing.

D188003A1 costs 95 EUR in the EU, which is kind of insane anyway. Meanwhile, an original BMW N57 camshaft cover gasket is around 32 EUR. At least VW didn’t make the cover plastic like BMW did. Anyone used Elring 777.792 ? Is it a decent aftermarket sealant? It’s only about 15 EUR. From what I can tell, removing the cover isn’t too bad compared to those single-camshaft Lupo petrol engines, where the cover is also part of the camshaft bearing assembly.

I had this issue, and the cause of the stalling was misfiring. In the dark, I was able to see sparks jumping from the ignition wires. You can also hear each misfire clearly when listening to the engine. The problem was caused by several factors, a faulty crankcase breather and PCV system, poor-quality ignition wires and incorrect spark plugs.

I think the 3&4 is selected by not rotating the selector shaft at all, just by pulling or pushing it. 1&2 and 5 is rotated littlebit to each side, reverse demands more rotating. then plastic rod no59 is alright, otherwise you would not be able to switch in 5th gear. Some problems to turn the shaft to other side.

Part no 11 definitely missing then, it just wears off, you can pull the shifter boot and see it yourself instantly.

3rd and 4th is normally nor left nor right, to select these two gears you should only need to push selector up and down. If you can select first and second gear, and also reverse, then part no 11 is worn off and the metal ball on part no 10 is not big enough to switch left/right enough, might be someone has moved the selector adjustment at bolt no 65 to right side (i dont remember, either thats up or down on bolt 65, but it should be tightened in free hanging position), to solve problems with switching in reverse. without part no 11 you should have problems to engage both reverse and 5th speed. Might be some more bushings are worn out and cause this, but I had the most worn out lupo in world and they were good enough to select all gears. if you cant source genuine part no 11 you can also use thich rubber hose on bottom pin of no10. Then you will need to adjust bolt no65 again back to normal. … or your selector is fine and if you cant find 5th gear by twisting and pulling/pushing part no64 manually, open gearbox end cover to check 5th speed gear and selector fork, nothing hard to do it, but hopefully its only selector problem.

This is low oil level problem. Once made same mistake. Wasnt able to shift speeds normally, didnt understand whats going on. It was permanently in 5th gear, but drivable. Removed gearbox end cover, pulled off 5th gear. Replaced needle bearing, toped up oil and it was good to go. Try removing 5th gear and check the gearbox, it might still be good. The aftermarket INA bearing was 10ish or something like that.

Faulty oil pressure sensor makes your engine bay look the same

Is it louder when you break with gears? If yes cone bearings are bad.

It’s tricky to remove this front panel without damaging anything, but once it’s off, I’ve never had any problems pushing it back on. Put everything in place, except the front grill, turn signal lights bolted on, then install this piece by pressing the clips into the wings, and finally install the rest and front grille. I’ve done it at least five times, and I haven’t noticed any problems with this design, except for the removal part.🙂

First, it’s not really a coin holder, that’s also why it failed to hold your coins. Second, you can easily remove the holder from the frame and inspect it. If this one no longer works, it’s best to get another one from a scrapyard. A lot of VW models have exactly the same holders — for example, the very popular Golf Mk4.

Get the wires under the plastic by any means — that way, they won’t be visible when you install the seats. Although visible speaker wire IMO won’t do much harm in this case, it’s still better to hide it 🙂

No need to drill the carpet 😅 Just run the wires under this part of the carpet — the rest is accessible from under the seat, and after you remove the center plastic cover

Excellent result, a pleasure to watch! 🤩 Usually in such processes, the unpleasant aspect is that everything takes a very long time — how long did it take you to make such an intake manifold?

Very nice, thanks for sharing 👍 All FIA homologation forms are available online — I love looking through them, true engineering masterpieces. Pages 38 to 68 cover the Polo S1600 homologation form.