I just took it in to work and showed the old boy that sorts out any bits and bobs I need making and told him what needed doing and how hard they are supposed to be. He looked at it, scratched it with a drill bit and said "that's fuck all, i'll bring it back to you in 5".

5 mins later he was back to me with a warm pulley with a bigger hole in it . When I asked how he did it he said he used the pillar drill and (iirc) a carbide bit, had 2 done now and he's never had an issue with them

I can find out exactly what sort of drill bit he used if you want mikey?

Edited 28 April, 201214 yr by Mclovin

Does anyone know if the main bearing/crank bearings cap bolts are stretch bolts and do you guys replace them when swapping cranks and such.

Cheers

Yes please Guy, old boys like that are worth knowing, their knowledge is priceless too these days.

Does anyone know if the main bearing/crank bearings cap bolts are stretch bolts and do you guys replace them when swapping cranks and such.

Cheers

Yes, yes. Do not re-use them or you risk throwing a rod through the block.

Had a word with him this morning mikey and he used a stellram bit which isn't quite as hard as a carbide bit apparently, so if you can't find a stellram jobbie a carbide bit will do the job no worries. He also used a manual lathe and not a pillar drill as I wrongly said further up

Can anyone provide suitable torque settings for bottom end?

AFH main bearing caps

AVY rod bolts

I still dont understand this roller pulley shit.

What bit are we drilling here?

Is the pulley from an AFH but your drilling out the middle of it to fit an AVY?

And it goes where a roller would normally be on the AVY?

Fuck man. I'm too tired for this shit.

I have photo's but can't be arsed to go searching for them right now, if I can be arsed tomorrow I will, if not, well you'll have to use your imagination

Both the avy and afh have a relay roller that bolts to the same place on the block, the problem is the bolt used on the avy is bigger than the one used on the afh. Meaning that when you go to bolt the afh relay roller on to the avy block, the bolt you need to match the threaded hole in the block won't fit in the hole in the relay roller so the hole needs opening up

You can't use the avy relay roller because the avy uses a much thinner cam belt than the afh because the avy uses a twin cam belt setup and the afh just uses a single cam belt. So the afh cam belt is too wide for the avy relay roller

Simples

Can anyone provide suitable torque settings for bottom end?

AFH main bearing caps

AVY rod bolts

Can anyone provide suitable torque settings for bottom end?

AFH main bearing caps - 65 Newtons (not stretch)

AVY rod bolts - 30 Newtons plus a quarter turn (stretch)

I might have a go at this...just put the 1.6 crank/pistons/rods into an AFH with a set of cams, simples?

Yep simples, the only real benefit of using the avy block is the oil squirters, but with that block comes other drawbacks. The thiner head bolts, the machining of the relay roller and the fact you can't just buy a full AFH head gasket set and be done with

I'm looking at machining my block to take the AFH head bolts and i'll also look at if/how I can use the AFH head gasket

Does anyone know if with the AFH they do thicker head gaskets for if the heads been skimmed like they do with some other engines? I've never seen anything mentioned about it so it probably not but thought it was worth am ask just incase

Yep simples, the only real benefit of using the avy block is the oil squirters, but with that block comes other drawbacks. The thiner head bolts, the machining of the relay roller and the fact you can't just buy a full AFH head gasket set and be done with

I'm looking at machining my block to take the AFH head bolts and i'll also look at if/how I can use the AFH head gasket

Does anyone know if with the AFH they do thicker head gaskets for if the heads been skimmed like they do with some other engines? I've never seen anything mentioned about it so it probably not but thought it was worth am ask just incase

Yeah when I next come to take the head off my 1.6 afh, i'm definitely going to drill and tap the block to accept the afh head bolts.

Don't trust using the avy ones, because they are thinner, when you fit them it is hard to keep them straight without using some kind of bush, and i'm guessing that this will affect the torque setting as the bolt is potentially sat at an angle.

McLovin - Did you notice any problems with the matching of the avy head gasket to the afh head? I didn't really notice much tbh but i think others have with the lining up of the oil ports.

Drilling the relay roller is a piece of piss, if you dont have access to something to drill it out with then you could use the stud method but seems a little dodgey

Yep simples, the only real benefit of using the avy block is the oil squirters, but with that block comes other drawbacks. The thiner head bolts, the machining of the relay roller and the fact you can't just buy a full AFH head gasket set and be done with

I'm looking at machining my block to take the AFH head bolts and i'll also look at if/how I can use the AFH head gasket

Does anyone know if with the AFH they do thicker head gaskets for if the heads been skimmed like they do with some other engines? I've never seen anything mentioned about it so it probably not but thought it was worth am ask just incase

Yeah when I next come to take the head off my 1.6 afh, i'm definitely going to drill and tap the block to accept the afh head bolts.

Don't trust using the avy ones, because they are thinner, when you fit them it is hard to keep them straight without using some kind of bush, and i'm guessing that this will affect the torque setting as the bolt is potentially sat at an angle.

McLovin - Did you notice any problems with the matching of the avy head gasket to the afh head? I didn't really notice much tbh but i think others have with the lining up of the oil ports.

Drilling the relay roller is a piece of piss, if you dont have access to something to drill it out with then you could use the stud method but seems a little dodgey

We never had any issues drilling out the roller either (think we've done 3 now) but loads of others have said they have had problems with snapping grill bits.

I can't remember having any issues with lining up the HG but it was a while back now

Jamie both the AFH and AVY use metal HG's

Harris briscoe got something like 156 with everything but the mappable ignition setup, mot sure how much difference it would make to peak power?

AVY is an allow block too isn't it?

Also what's the concern about the M9 head bolts? They're good enough for the 125hp GTI?

AVY is an allow block too isn't it?

Also what's the concern about the M9 head bolts? They're good enough for the 125hp GTI?

The problem with them is that they are too small for the holes in the afh head and risk moving around when torquing them up. Also they might be fine on a 125bhp gti, but probably not so on a 180ish boosted afh/avy pikeytech special

Edited 26 September, 201213 yr by Mclovin

Avy sump is bad news on lowered polo's, its easy enough to smash/ware through the steel sumps so fuck taking the chance with an alloy one

Another thing.. Struggling to find AVY piston rings atm :/ ..

http://www.ebay.co.uk/itm/251145881475?ssP...984.m1423.l2649

Message him and ask him if he has any more

Getting downpipes shortend and rewelded hopefully. Guessing using a shallow pick up is a no no on AVY ?

Not really looked into this but i've seen alot of people saying early and late afh ? whats the crack, can one accept it and other not ?

Early afh takes the same pick up as the mk2/f style engine so the shorter pick up is a direct bolt on. The late afh and avy use a totally different design of pick up, it can be shortened but would need to be modified rather than just swapping it out. I'll be doing this on mine and by looking at it its just gonna be a case of cutting a bit out of the pipe and welded it back together to give the right length for the shallower sump. Whether its that simple in practice only time will tell

What would u class as early ?.

Cant use the afh block and avy internals with a shorter style pick up can you :/

No you would need to also use the oil pump and pick up to match the crank which will be the later direct drive one. The change happened somewhere between 97-98 iirc

Yeah, the problem is that the earlier AFH engines (and the engines before that), used a chain driven pump, which could be "split" in two, and you can remove the pickup.

The problem with the newer AFH's, and after that, is that they made the oil pump effectively part of the crank, so you can't split it like you can with the old one.

You'll need to chop it. Using AVY internals in an AFH block is fine (any block), but you have to use the oil pump that matches. In this case - the 1.6 versions, it'll be the crank driven pump..

The pickup can still be split from the pump like the early ones can, its just that they are a different design and not interchangeable early to late. I did have some pics comparing the two but couldn't find them last time I looked

I've cut and welded my late afh pick up, its in my thread.