Well I was deffinately right about the brakes.. Stuck my head in the arch today to have a wee nosey, and spotted this. No wonder I felt dissapointed with the brakes !!

Drivers side:

Passenger side:

So it seems I'm only using about half of the braking area on the disk. Does anyone have any suggestions on this matter? The pads are deffinately the right ones for the G40 calliper/disk combo so I'm stumped.

On a more progrsssive matter, I've made a start on fitting the 6N fusebox to the underdash tray

First of all, I worked out where i wanted the fusebox to sit and went to town with the slitting disk on the grinder

Next step, I modded up the coin holder to house the OBD plug, you can also see where the fuse box will live. I think Ill have to make up a strip to cover that rainbow of fuses

So the next step will be to attatch the fusebox to the tray, splice in the wires to the ignition switch, then plan how to get the engine loom through the firewall into the bay.

So after a fantastic xmas/new years break, I'm back on the case. The MOT expired, and even though i hadnt planned to fit the engine till later in the year, I've decided to take the car off the road and get the AFH running the EFI in the car.

The first pic below is my car in the garden in front of my sorry looking original coupe (parked in front of the garage). this took the good part of an hour alone, just to get from the drive to the garage!!

This next shot is of the engine as it stands now. I finally found the head bolts from a website called enginestuff.co.uk for a total of £26. WAAYYYY cheaper than the dealer and will do the exact same job. see this thread if your interested. Big thanks to McLovin for the link!

http://www.clubpolo.co.uk/forum/index.php?...p;#entry2234591

So the engine just needs the alternator, O/S engine mount, and the clutch and gearbox fitted before i can get it in the car.

Tuesdays progress is shown here. disconnected everything from the engine ready for the lift ..

And tonights progress. after buying 12M of nylon rope, and digging out my pullys. Out it same

So the next step, be it be tomorrow, or the weekend (cummon who works on friday night?), will be wiring in the AFH loom and ecu(which ou will see is already fitted in the pic above). Also bolting on the coupe S enginemount, alternator, clutch, fly wheel, pressure plate, and starter. Once these jobs are done, I hope to see it running within hours.

I think I've just about got my head around everything now. as long as it carries on this smoothly (although i did have to grind off a rounded driveshaft bolt earlier), I'm hoping to have a video of it running by next weekend as i have 4 days off. Then its just MOT and a long welsh B road drive and perhaps a spin up brecon way to run it in a bit(any locals want to join?)

Oh and appologies for the god awful pics! it was 10PM by the time i took them and this samsung isnt up to much in low lighting lol

The excitment of taking this for a blast, and an approching show/festival season, is spuring me on to get the job finished now :-D

I find it easier to bolt the alt on once the engine is fitted mate as it gives a little bit more room when manouvering the engine around as you lower it in. Are you keeping the cars original gearbox? if so would you hate me if now you've taken it all out if I told you you could of left that all connected to the car and just swapped the engine?

Coming along nicely tho mate and properly jealous of your garage

I find it easier to bolt the alt on once the engine is fitted mate as it gives a little bit more room when manouvering the engine around as you lower it in. Are you keeping the cars original gearbox? if so would you hate me if now you've taken it all out if I told you you could of left that all connected to the car and just swapped the engine?

Coming along nicely tho mate and properly jealous of your garage

yeah I've gotta admit having a double garage is making the whole process much easier.

good call on the alternator ill bare that in mind.

I am keeping the original box, and I know I coulda left it there in the bay, but wanted to get it out to make sure my clutch/flywheel setup works together, as the engine came with skoda felicia stuff on it, so I just want to make sure its all gonna work before i lower it into the bay. when i bought the engine, it came with a spare clutch, which looks to be roughly 10mm bigger than the coupe S one, and fits the spline etc, so hopfully i can run with that.

I've just come in from the garage after soldering the 3 wires into the igition switch so I'm ready to run the rest of the wiring from fusebox to ecu in the bay.

I still cant see where i can get the blocks that plug into the fusebox, through the firewall into the cabin.. Give us a clue mate i want to hear the ecu click or buzz to put my mind at rest lol.

right now though, I'm having an asolute nightmare removing the skoda flywheel off the afh lump

I made a hole in the bulkhead near the cars fuse box, i'll get a photo tomorrow

Use the bigger clutch mate, I doubt the coupe s one would be up to the job tbh

looking good mate, shame about the coupe in the background though, you gonna do anything with it?

SO... I've wired in the fuse box, and temp run the 2 main wires (live and earth), out the window of the car, and onto the battery, just to try and get things going. :-)

I've connected the ECU to the loom, transponder, and ring, and I've taped the key to it.

The first few turns of the ignition, it powered up the fusebox for 3 seconds, and the more I've tried it, I've got it to stay on for 7 seconds, but then it clicks again and all power is lost. should i be worried:-? I'm hoping this goes away when everything is connected up ! I had a feeling it would be the wiring that would slow up this conversion.

Mcloving: OK ill get the hole saw out. I was thinking behind the battery would be a good place to drill. which clutch have you got in there then?

Erixtar: cheers dude. No plans for the 'A' reg thats parked up. the shells in great condition but i dunno what to do with it if I'm honest.

Edited 12 January, 201214 yr by Leggy

How so you know its loosing power if nothing is plugged into the mk4 fuse box? When you say its only powering up for a mater of seconds are you sure that's not just the fuel pump relay doing its priming thing then clicking back off?

make it into a track day beast! haha

How so you know its loosing power if nothing is plugged into the mk4 fuse box? When you say its only powering up for a mater of seconds are you sure that's not just the fuel pump relay doing its priming thing then clicking back off?

Well when i turn on the ignition, you hear a click, then 3 seconds later, or 7 seconds now lol, it clicks again. Just to test i plugged in the fuel pump, on ignition on, it fires up, then after the second click, it cuts out. I know they aint meant to be run dry but I'm only testing. its not like its running for a long perios which would fuck it up. Some reason the imob is kicking in.. grrr

I have thought about making a track slag out of it, but more importantly for now, lets the get daily running again. I'm snarffed off with trains already and its only been a week

EDIT: just read your PM. So its just the pump priming, but shouldnt it stay running after the few seconds. If this is normal then its panic over :p

Edited 12 January, 201214 yr by Leggy

immobiliser?

haha. try working on them! tis efffort!

Most fuel injected cars do it, when you first turn the ignition on it primes the pump to get fuel pressure into the system, then once you start cranking the ignition it fires the pump up again. I'll get a video of mine doing it tomorrow if you like to put your mind at rest?

As long as its been wired in how it was labeled up you shouldn't have an issue with the immob, besides you woukdn't be able to tell that you were having issues with that until you were in a position to try and start it, just turning the ignition on and off will just let you know you have power to the fuse box

ahh i get you nice one.

so how hard actually is the efi conversion? id love to put mine on injection but I'm too lazy. reckon it gives better economy than carbs?

Looking good chap!

Might see you in my Mk2 AFH in a few months down Swansea as half my family live around there in the Mumbles.

Ok cheers mate. i remember the NZ used to do it now actually. you tend to forget these sorts of things after running with a a dodgy peirburg carb for so long. Dont worry about a video it'll be alright. So in theory I'm ready to bolt it in and connect it all up now. HAPPY DAYS! Oh and what you said about using a mk3 coil, not a chance. the plug for the coil it completely different to the fitting on it. And I'm still short a knock sensor wire if anyone has one 'knocking' around... I'll leave now

I've never run carbs but with the efi its not bad, I don't see any thing like the 40+mpg some people claim the afhs should get but then I'm not the type to take my time for the sake of fuel economy

Looking good chap!

Might see you in my Mk2 AFH in a few months down Swansea as half my family live around there in the Mumbles.

AFH mumbles meet! I work in the civic building opposite the prison so give me a shout when your down next.

And I'm pritty sure EFI would be better on fuel than carbs, especially if they havn't been professionally set up.

Can you not just repair the knock sensor wire mate? And I wonder if its the nz coils that are different then, sure I've swapped between mk3 and mk4 coils before, but then it wouldn't be the first time I've got confused either lol

nz coils have a weird 6 pin plug , i dont know why though

Ill have a look to see if it can be repaired, but the wires have ripped clean out of the sensor.

And yes, the nz has some ridiculous 6 pin plug. Why the fuck would they do that when it's pritty much a GT ill never know.

So, how much have i got done this weekend? Not quite as much as what i would have liked if I'm honest, but still, as long as its forward progression then i guess i can't grumble to much.

To start the weekend, I thought I'd try out a new product, and bought some gunk engine greese and oil cleaner. It claimed to removed the wax aswell but wouldnt shift the VW waxing in the bay. I Dont really mind as its there to protect, but it did shift so much other crap out of there that was collecting.

The results..

BEFORE:

AFTER:

Next I finished up attaching the fusebox to the undertray with a simple custom bracket to make it easier to remove in future. Just remove one screw, pivot the bracket, and its free. Might give it another coat of matt black :-)

Next job was to remove the required parts from the S engine, and get them fitted up to the AFH.

I started with the gearbox end, so out came the flywheel lock tool. Swapped over the clutch, fly, and back cover from the S and bolted them straight to the new block.

heres the Before picture again, showing the felicia adapter plate, and mega heavy, and deep fly wheel, and below is after I'd fitted up the stuff from the coupe S.

And heres time timing belt end. After a good clean with the gunk, I fitted up the engine mount, a trimmed down timing belt cover bracket, and the actual belt cover.

And a modified lower alternator bracket. I just had to give it a simple 'rounding off' around the bolt hole where it fixes to the block to give the required clearance. Now even although this fits nicely, I'm not 100% sure I can use it, as I havn't swapped the MK4 pulley onto the MK2 alternator to see if it has enough adjustment, but it does bolt up the way it used to.

So thats about all I've done this weekend. Next weekend I have 4 days off, so by then, I'd like to have the following done:

*gearbox and started motor attached to the block

* the wiring loom in the bay and hooked up to the fusebox

*fuel pump mounted ready too be plugged and plumbed in

*get the mk4 alternator pulley off (can anyone give me tips on this), and fitted up to the mk2 alternator

Should I get the above list done, then next weekend should seeme lifting in the engine and plugging it in. and fingers crossed, firing up aswell!!

A bit of progress from yestarday. I went out and bought a 50mm hole saw from machine mart (cost me a staggering £17 with the fitment peice!!). So i set about drilling through the bulkhead to feed the wiring loom through to the fusebox. In the picture below, you can see the hole and the whole loom comming in under the steering wheel. They line up perfectly with the fusebox which is fixed to the dash under tray :-) You can see I've used a spare loom gromet to stop the wires getting chewed, and prevent any fumes or moisture entering the car. I also finished soldering and taping the remaining wires for the transponder box, and the OBD socket.

This shot shows the otherside of the bulkhead. the new loom come through just behind the battery, then runs to the ECU.. I've arranged it all a bit neater than it looks here as i took the pic when i was just laying the wires out to check everything would reech where it needs to go in the mk2 bay.

Tonight I've tried to bight off more than i can chew. Number one, its solid to torque up head bolts when the engines balancing on stuff to keep it up right. number two, after fitting the clutch, I've been trying to get the gearbox back on, again, its solid when everythings moving. I'm sorry i didnt try to borrow an engine stand off someone ! I'm hoping my dad will come fill in as an 'engine support' while i finish these 2 tasks later this evening lol

A big thanks due here to my dad. In all fairness, within 5 minutes of him finishing work, He was in the garage, supporting the engine for me to torque up the head bolts, and slide on the gear box!

I was about to bolt on the starter too, but realised i still havn't found a solution for this damn broken knock sensor cable shown below. Does anyone know if these types of connections can be repaired? If not I'm gonna cut an identical plug off an old MK3 polo loom with enough cable, and solder it on. once this is done, I THINK, I'm ready to put the engine in the bay.

Gunk is good shit

What's that thing hanging off the front of your block with the two holes in, is that part of the engine casting? And that flywheel is fucking huge!

As for the mk4 pulley, I can't remember how I got mine off but I'd imagine it would of involved either mole grips or stilsons and a socket and ratchet (thats how I normally do the v belt pulleys anyway). Just make sure you put the slot in the pulley for the woodrift key to slot into cause it really isn't worth the risk of that coming undone and firing the alt fan towards your timing belt. I did it using a hacksaw and a file and it, so easy its not worth not doing