Gavin's cheapy but getting more expensive GTI ;)

[h100vw]

Did you apologise to those pistons and rods before the go into their home?? lol.
Nice work i was going to go as far as that with the AGU, have stared at it many times as its still not hard bolted to the car, the fact i have to fit my low level sump made me think about going up with strength, but thinking itll be strong enough, you will vouch for that re your old A3, it was loos as hey
Might do nationals too this year. in what dont know might do what i did last time
Cheers
Jmac

No apologies to the pistons Jimmy, I just bust down the door.

I reckon the JBS04 will be plenty in that Polo mate, the AGU can handle that.

Greg, Make sure you wire up the boost cut on that water kit, be a shame to have it all come tumbling down if you run dry.

Gavin

[Polo GTEye N9]

Last full engine I built was a 1275 mini when I was 21. Done a few head rebuilds and head gasket replacements in the past but I am by no means a skilled engine builder.

On the other hand, I can read English and use google.

The biggest obstacle is information and tools. There's a youtube video on fitting the rods, which I watched before starting on Litos. There's a few tools that you wouldn't find in the average tool box but they don't cost much at Trade tools.

I bought piston ring compressor, ring expander, Ribe bit for the head bolts, some external torx looking sockets to undo the rod bolts and cam caps, flexi hone tool and oil. I already had 1/2 inch and 3/8 torque wrenches.

Sometimes it's not enough to have just one 6mm allen key though, ball-ended or different lengths are required to make the job easier.

What I am saying is don't be afraid to have a go, you were there to fit the turbo. It's not really any more complicated.

I always told people who asked what I'd do if I couldn't put it all back together. "Take it somewhere and pay. I'll have saved half the labour".

Practice makes perfect, I was definitely getting quicker as I went along with the rods and i didn't have to do any twice because I put them in backwards.....

I still reckon the 3 times to 50lbs is my method. Unless you have some plastigauge Jesse??

Gavin

Well done again, Gavin.

My first car was a Cherry Red with white roof 1963 Mini 850cc, with starter button on the floor and sliding windows. I brought a Haines Manual and pulled out the engine then stripped it done and rebuilt the gearbox. Never been on the tools prior to that, had no idea and I was 16 yrs old. I loved that Mini, it was so much fun. Actually the Polo is the car that has become as much fun and so much more reliable. I spent far too much time replacing or repairing the Mini front drive shafts. Gavin I am proud of you, bravo. Go you good thing. And you know your way around the yard with a lawnmower too.

Just an idea but had you thought of balancing the pistons etc while you have them out? Cheers Al

[h100vw]

Well done again, Gavin.

My first car was a Cherry Red with white roof 1963 Mini 850cc, with starter button on the floor and sliding windows. I brought a Haynes Manual and pulled out the engine then stripped it done and rebuilt the gearbox. Never been on the tools prior to that, had no idea and I was 16 yrs old. I loved that Mini, it was so much fun. Actually the Polo is the car that has become as much fun and so much more reliable. I spent far too much time replacing or repairing the Mini front drive shafts. Gavin I am proud of you, bravo. Go you good thing. And you know your way around the yard with a lawnmower too.

Just an idea but had you thought of balancing the pistons etc while you have them out? Cheers Al

Thanks Al.

I could spend a fortune on it easily. Personally, I think that the std hardware is pretty good. I might just weigh the rods and pistons end for end, out of curiosity. Not planning on revving it to the moon, the valves won't handle it and the turbo is too small.
There's no chance of a GT28xx going on there in the future, so I don't see any merit in piling money into the bottom end.

I am going to get a multi-angle valve seat job done though. Got a place in Mansfield in mind for that.

I honestly haven't had this much fun, in clothes, in a long time I don't get a kick out of working on aircraft at all. In fact I will do almost anything not to work on them.

Not sure I'd be up for a day job doing it, like Jimmy does though??

Gavin

[Machine]

Good on ya, Gavin.

[Jmac]

100% correct Gav, it does take the enjoyment edge off it, thats probably a major factor why my weapon in the shed is still on stands, all the time supped fixing other broken ones, cant complain too much mind, time is freeing up a bit and more shed time is on the cards. Crazy mate we polar opposites thats why i went into the aircraft industry. Anyway if you got the time and the zing is there why not do what your doing, keep it up, look forward to a shot of it when done
Cheers
Jmac

[h100vw]

100% correct Gav, it does take the enjoyment edge off it, thats probably a major factor why my weapon in the shed is still on stands, all the time supped fixing other broken ones, cant complain too much mind, time is freeing up a bit and more shed time is on the cards. Crazy mate we polar opposites thats why i went into the aircraft industry. Anyway if you got the time and the zing is there why not do what your doing, keep it up, look forward to a shot of it when done
Cheers
Jmac

The pressure of putting food on the table makes me keep the day job. Plus the amount of time I get off to do stuff is great.

I look forward to a few peoples faces aching from grinning after being at the wheel. Tony Sharpe is coming round tomorrow to borrow my Haldex filter tool. He drove the Polo January before I tweaked the timing, looking forward to his comments. It was only slightly up on a Phase 1 before the tweaking.

Gavin

[guile]

schweet work mate, keep it up. wouldn't mind you taking me for a spin when its all done if thats cool. not back for a few weeks now though, boo....

[h100vw]

schweet work mate, keep it up. wouldn't mind you taking me for a spin when its all done if thats cool. not back for a few weeks now though, boo....

You can drive it mate, it's quite a thing. Even 4 up with the dog on board today, it's still nippy as!

Gavin

[Polo GTEye N9]

You can drive it mate, it's quite a thing. Even 4 up with the dog on board today, it's still nippy as!

Gavin

That would be a small dog Gavin. Pity it was raining when I was at the wheel to refuel it, when Lito had your Polo as a loaner.
Cheers Al

[h100vw]

That would be a small dog Gavin. Pity it was raining when I was at the wheel to refuel it, when Lito had your Polo as a loaner.
Cheers Al

Ok so no one is driving it now, even me................ Broke down on the way home from work. VCDS said cam position sensor. No probs there's one on the spare engine. Calls for back up, wife rocks up in S3. Meanwhile, a wheel falls off a Nissan Patrol. No nuts, I found one just up the road.

Got sensor and a jack for the Patrol. Dude fixes Patrol, new cam position sensor nil fix.

So, I'll be missing Church again. Or maybe I should go and ask for help?

Gavin

[jboogie]

Ok so no one is driving it now, even me................ Broke down on the way home from work. VCDS said cam position sensor. No probs there's one on the spare engine. Calls for back up, wife rocks up in S3. Meanwhile, a wheel falls off a Nissan Patrol. No nuts, I found one just up the road.

Got sensor and a jack for the Patrol. Dude fixes Patrol, new cam position sensor nil fix.

So, I'll be missing Church again. Or maybe I should go and ask for help?

Gavin

No good mate.

Any other ideas on what could've caused the problem?

[Machine]

How did the breakdown occur? CEL light, stall, weird noises? Details, Gavin!

[h100vw]

How did the breakdown occur? CEL light, stall, weird noises? Details, Gavin!

Pulled off motorway, sub 7 on the L/100. Stopped at first lights, set off for next set, coast to next set, silence. Cranks no signs of life. Roll and crank in second across the junction to safety.

Out with laptop and VCDS, cam position sensor fault. I called my wife for back up, only 5 minutes from home. Grab spare position sensor, everybody keeps one don't they?

Return and fit it, nada. Thought there might have been no fuel? Pump running and squirts out the FPR when it primes.

A bit of a read last night says check fuses, so that's first on the list. Go with the easy stuff first.

Gavin

[team_v]

Pulled off motorway, sub 7 on the L/100. Stopped at first lights, set off for next set, coast to next set, silence. Cranks no signs of life. Roll and crank in second across the junction to safety.

Out with laptop and VCDS, cam position sensor fault. I called my wife for back up, only 5 minutes from home. Grab spare position sensor, everybody keeps one don't they?

Return and fit it, nada. Thought there might have been no fuel? Pump running and squirts out the FPR when it primes.

A bit of a read last night says check fuses, so that's first on the list. Go with the easy stuff first.

Gavin

Fingers crossed it's just a fuse then mate.
Maybe you should have bought the Mk2 Jason got, things were much less complicated back then.

[Machine]

Definitely. Simplest explanation is most likely, especially knowing you've been thorough and careful throughout your build

Popcorn's on...c'mon fuse...