ObjectiveAway

I bet the cause is worn out gear selector, therefore you actually try to push your gearbox shift rail in position between 3rd and 1st gear. You can pull shifter cover (1) and most probably a lot of parts will be worn out, but part No 11 was gone for mine gearbox. Worn out parts No 54 and 62 makes sideways freeplay as well.

Most Lupo's have 085 gearboxes and conical bearings at the end of shafts starts to make sound because of wear out, starts to sound similar to gearboxes with straight cut gears, they whine, you can especially hear that in low speed. The only way to solve it is to open the gearbox and replace the bearings, but it is not easy repair, therefore it is cheaper to replace the gearbox with another used one. INA(~100£) and VW OEM (~300£) bearings are available for these gearboxes, but it will coast at least 500£ in labour and almost none will agree to do the work. I have heard a lot of these gearboxes dies straight after you change the oil. A guy told me these gearboxes needs 500ml extra oil, thats 3,2l instead of 2,7l, but he didn't explain it to me and I havent tried to fill that much oil in my gearbox yet (I am aware older 085 gearboxes needed 3,1l oil, but thats not the same)

I didn't got my Lupo with original head unit, but speakers sounded terrible with any aftermarket unit, but sound changed a lot when I added crossovers to split frequency between tweeters and door mid range speakers. It was very easy, not much time consuming and invisible update.

I already have new timing belt kit from INA installed, new lifters are coming next, I cant decide to eighter buy another head and prepare it before instaling or replace just the lifters and forget about it. 8 INA lifters coasts less than 25£, KOLBENSCHMIDT about 35£, i will buy new ones, thank you for offering your spare ones.

Remapping. EGR valve don't affect fuel consumtion and output power, same like remapping, EGR just affects emissions qualitty.

The qualitty of some details in this car is very low, therefore I wouldn't trust the overall qualitty of mods is normal. For example I can list exhaust pipe, which is turned right, and interior which looks very bad, don't even have mats on floor.

Like from me, well done. My Lupo's 1.4 8V MPI (AUD) engine is noisy like diesel, however compression was well, after reading this I know some lifters are definitely dead.

Its even more pricey than 6N0711167A, but at least I see plenty of them available.

Thats 02J gearbox, is this Lupo gearbox? I have M8x1,25 57mm on my car.

Have seen some of these manuals before, but not all together. Thank You!

Some time ago OEM was available for around 15£, but I don't see them available anymore. At least 6N0711135 OEM and aftermarket are still available. Looks like its not the same, but might be this can be used as replacement. P.S. Actually there is a little mistake in title, because most of 085 gearboxes does not have cable shifters.

Is't that only width and height of tire which slows you down? I drive 155/65 R14 and they saves about 20% of fuel compared to 175/60 R14 and 175/65 R13.

The fact you have high rpm's on 140km/h not always means only 5th gear is short - if the final drive is short, whole your gearbox will be short and 5th gear replacement will not help much. You have 02T gearbox, you must write down gearbox identification letters, because there are a lot of 02T gearbox modifications. You can check some of the modifications and ratios of 02T gearboxes on this website. 37:50 is longest 5th gear I have noticed on 085 and 02T gearboxes.

cluster removal is very easy for Lupo, just remove the sunguard from above, and remove the cluster, few minutes work.

Coil packs are very important for your engine perforance, I wouldn't trust 20£ set more than OEM top part and new 20£ bottom from high end manufactuer.

It is possible to buy the broken ceramic part seperately (which is actually the cheapest part), therefore you don't need to buy whole coil pack.

Try to look at ignition parts in dark, you might see sparks around spark plugs or coil packs. But thats not cause, its result. CCV system malfunction can cause misfires.

There isn't really much to adjust. Look at the picture, No 6 and 5 arent adjustable. No 3 and no 32 can adjust camber, to change toe just adjust tie rods, which are connected at No 23 in this picture. Caster can be adjusted by moving whole subframe. As long as I understand you might want to get right alignment without adjusting tie rods, but thats silly if you have wheel alignment machine.

Yes, you are right, there is no plug and play swap to get rid of 085 gearboxes, however I don't understand a lot of problems You mentioned, Mitchell told only difference between those two engines is starter motor position, if thats true, there should be no problems, to make directly swap from Lupo AHV to Golf AHV engine, but starter motor would need rewiring due to change of position. I don't see why would ECU even notice this swap. Im thnking about 02A gearbox, therefore no problems with shifter (because shifter tower is the same), but would have problems with hydraulic clutch (only in some rare ocasions 02A gearbox has wired clutch); gearbox mount; driveshafts. I already have a spare 085 gearbox for my Lupo, but 02A would be great swap.

Is it possible to swap Golf gearbox in Lupo by using Golf AHV engine block?

Yes, for SDI will suit. Polo 6n2 1.4 mpi 3door subframe is the same.

I always use pliers for this, it is possible to hold the metal clip in a way which is not interfering bolt movement. I think this might not be your case, but new bushes might be tough because they are made with 16, 18 and 20mm holes and you can squeeze in a bush with 2 mm smaller diameter than your ARB.

I just drilled the two sill screws off, then drilled completely trough and made holes for new 6mm bolts in the sill, I advice to not spend too much time on these two. It was possible to unscrew this one without removing any additional parts, but correct way is to remove scuttle panel. It was hard to unscrew the philips bolts near door hinges, I advice to replace them with hex bolts alterwards. You should remove front trim, because two plugs are attached to wing, since you need replacement of both wings you will not regret of removing it, otherwise you can break it in the narrowest place - right under the headlight. You should remove front whole bumper to remove the wings, I think slight heating of bumper will help to not make crack in it. I think this is exactly Lupo wing, except a single bolt near scuttle panel is missing in this picture. I don't know what workshop manual this is, but there is one for lupo on this page: https://vwts.ru/vw/lupo/vw-lupo-body-repairs-exterior-eng.pdf

You should check gearbox code, might be ETD. You can see the code on several places of it, but this is my favorite 085 gearbox code location, since everybody can read it even if the gearbox is in enginebay.

Wow, thats great, didn't know all gamma radio units in lupo has this option.