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HOW TO: AFH 1.4 ->1.6 16v Bottom end conversion


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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!

DSC02731.jpg

see below

there was a way to grip the beast, but even with the beastiest drill at thier disposal, it merely just tickled the surface and wouldnt make a dent, so they put there heads together for 5 and came up with a turned down threaded rod which is tres perfect for my needs!

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

i've also discovered that the AFH cylinder head gasket is no good for it, it will physically fit, and all the water ways etc line up, plus the oil feed it fine... but the 3 oil drainback slots at the front are a slightly different shape on AFH blocks so you need to use the polo gti avy head gasket to fit it onto the avy block

100_0700.jpg

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

DSC02725.jpg

DSC02728.jpg

47759_467445876342_511441342_6892793_5509904_n.jpg

47759_467445881342_511441342_6892794_564173_n.jpg

47759_467445886342_511441342_6892795_4966043_n.jpg

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 **

Edited by nfbr
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