grungeisdead Posted September 13, 2010 Report Share Posted September 13, 2010 (edited) 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 needEssentialsHeadbolt - 036103384B ( x 10 - for 1 cylinder head)Polo GTI Headgasket 036103383QMetal Inlet Manifold Gasket 036129717GAFH Cambelt 036109119HAFH Tensioner 036109243JAFH Relay Roller - 036109244Water Pump - 036121005D/036121005MXIf RequiredPolo GTI/AFH Sump Gasket Sealant - D764004A2AFH Cylinder Head Cover Gasket - 036103483 D & 036103483 GARC/AVY Piston Ring Set 036198151C ( x 4 - 1 set per piston) - If requiredARC/AVY Crankshaft Bearing Set 036198491Alternator belt HB680G (Halfords) - For Mk1-3 Conversions using the Mk4 AlternatorAlternative SuppliersGSF132VG0180 TIMING BELT IDLER PULLEY PO 1.4 16V 95> 21.95 170VG0140 WATER PUMP PO 1.4 16V AFH Eng. 95> 26.75 ConsiderationsHeadbolts6n 1.0 AER & Non AVY GTI lumps have the correct length headbolts6n Polo 1 Litre036103384Bbolt, with multi-spilne socket headM9X1,25X138 / AER,ALLLupo GTI036103384Bbolt, with multi-spilne socket headM9X1,25X138 / AHW,AKQ,APE, AUA,BBY,AFK, ANM,AQQ,AUBPolo GTI036103384Ebolt, with multi-spilne socket headM9X1,25X97 / AVYThe correct part from GSF is01163CYLINDER HEAD BOLTPO 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 036109244the 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 belowthere 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 thereHeadgasketPolo GTI Headgasket 036103383Qi'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 blockFuelling & ManagementI 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 threads1.4 16v AFH mit 1.6 16v Lupo GTI Bottom End, PikeyTech® Conversion underwayMk1-3 Polo 1.4 16v FAQ + Conversion Guide, & General AFH on Bike Carb Guide.Fitting bike carbs onto a mk3, Parts neededsome picturesEnjoy!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 October 10, 2010 by nfbr 1 Link to comment Share on other sites More sharing options...
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