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Thread: VW Polo BUILD #3: CIAOS Continues...

  1. #31
    Join Date
    Apr 2018
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    Bayside, VIC
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    It's been an awful while since I've done an update; both literally on both the Polo and 3200GT
    I have hit the burnout wall. Still there but I think I'm gradually moving on from it, mostly my own fault as I just keep taking on more tasks and responsibilities than I honestly should.

    Anyway; brief catchup
    -December: Built the head; dismantled carefully, replaced all valve stem seals. Installed the Ferodo exhaust valves, kept the stock stainless intake valves, cleaned all of their carbon up with oven cleaner. Took a bit of convincing! Brian Crower retainers and springs. Looked pretty stunning; cleaned it up before storing it away for two months haha
    VW Polo BUILD #3: CIAOS Continues...-pxl_20211204_110658817-mp-jpgVW Polo BUILD #3: CIAOS Continues...-pxl_20211211_095737360-jpgVW Polo BUILD #3: CIAOS Continues...-pxl_20211214_103611214-mp-jpgVW Polo BUILD #3: CIAOS Continues...-pxl_20211218_020722149-mp-jpg

    After these, I sat and organised the crank. I had bought a a set of main ARP bolts from another fellow in Sydney and given I received them in a bag and not the official box, I did not realise they were for the larger tfsi caps!(if anyone need these, all yours). So that pushed me back until January to get the correct 201-5001 ARP studs, installing the oil squirters and crank in. But anyway, I've sat and measured everything; following 1.8t Crank Pulley Tool // 1.8t Stroker Engine Build - YouTube as my guide as to what steps should be undertaken.

    Calculated the clearances on all mains to be around 0.04mm+-.0025 and then confirmed these all with plastigauge.
    End float once in was 0.012mm -> calculated 0.0127mm from what I have measured, which matched up almost perfectly
    Crank deflection was a mere 0.01mm on the center cap.

    VW Polo BUILD #3: CIAOS Continues...-pxl_20220126_051337614-mp-jpgVW Polo BUILD #3: CIAOS Continues...-pxl_20220126_033956196-mp-jpg

    Balancing! This honestly was something that pushed the assembly back for a good while. I was able to sort the pistons, pins, clips and do those decently -all 397.43g. But.. conrods were a nightmare... I spent a solid 6-7hours attempting to balance them and in the end, had just given up as the values kept fluctuating by .6-.7grams. Handed them to an engine building shop and Frank got them all together beautifully. All to 582.1g

    VW Polo BUILD #3: CIAOS Continues...-pxl_20211211_074806396-mp-jpgVW Polo BUILD #3: CIAOS Continues...-pxl_20220204_101635983-mp-jpgVW Polo BUILD #3: CIAOS Continues...-pxl_20220305_060527001-mp-jpg

    Did a quick half day timing belt job for my brothers GTI. Thermostat left the building and we thought it would be best to get it all done. Boy were we spot on. would have kicked the bucket at any random point in time...
    Then had found the source of my squeaking noise! Dry polybush. Front LCA bush had managed to get dry enough that it would squeak from time to time. Then there was more work done there; had my steering boot with a leak. Took it out and out poured a substantial amount of power steering fluid. Good I topped up! Sorted that and had the LCA bolt back out after a pothole, that was fun too.

    VW Polo BUILD #3: CIAOS Continues...-pxl_20220306_073533701-mp-jpgVW Polo BUILD #3: CIAOS Continues...-pxl_20220102_064845232-mp-jpgAttachment 53893

    Piston rings threw me off the most:
    Top rings were .012-.013"
    Second rings were already .020-.021" (which initially didn't make much sense. like they are the wrong rings for this set, but they're not!)
    Oil rings were all .017-.018"

    Ended up taking it all off to
    Top: .017" |Sec: .021" |Oil: .018"
    which is plausible given the original math ended at .015", but then the optimal math for first ring ended up at .0164" *83.5mm bore* and then .004" to .008" off for the second ring(as specified by Carillo) so .019" for the second ring and oil rings being anything greater than .015".
    I am not going backwards now haha. It is what it is!

    Once that was done, lubricated and assembled; checking bearing clearance(ACL racing bearings so these were ok). brought to TDC and checked over with the dial indicator. Punched a dot onto the timing gear and with that; the remainder of the bottom end assembled with what I had. Am missing the pump bolts and the pickup tube lol.

    VW Polo BUILD #3: CIAOS Continues...-pxl_20220305_072933039-mp-jpgVW Polo BUILD #3: CIAOS Continues...-pxl_20220305_105941696-mp-jpgVW Polo BUILD #3: CIAOS Continues...-pxl_20220305_115746422-mp-jpgVW Polo BUILD #3: CIAOS Continues...-pxl_20220305_122901137-mp-jpg

    I just have the sump to weld together, all the pieces are cut up and fit together in the sump, haven't had the time at all... But yes,
    VW Polo BUILD #3: CIAOS Continues...-pxl_20220305_134002019-mp-jpgVW Polo BUILD #3: CIAOS Continues...-pxl_20220305_140653547-mp-jpgVW Polo BUILD #3: CIAOS Continues...-pxl_20220305_135808973-mp-jpg
    Anyway, went to put the head on. Put all the studs in, had it all lubricated and ready to tighten. Put all the nuts in and started the sequence. Got to #7 and the nut kept on spinning rather than tightening. Strange... kept going but I stopped because no other nut was like this. Took it off, snapped my allen key in the stud (trying to remove without taking the head off) and then gave up that evening.
    Next day took the head back off, and tried to see what is wrong with that stud/nut! It went on smooth and then.. stuck, couldn't back it off the stud whatsoever. Gav comes over and saves the day!

    VW Polo BUILD #3: CIAOS Continues...-pxl_20220306_024254730-mp-jpg

    Got the nut off, tap into the nut, die on the stud and then attempted to reassemble(seemed as though the nut had a defect!); and gave us the same dilemma; except Gav kept going on that nut until it eventually grabbed and began getting some torque down. Was super sketchy by the end only on this stud as it began creaking and I swear I could not get any more lube on these studs! smothered them before the head and also put plenty on the bottom of each nut! It's all done. no more

    Still have to get the head assembled, timing done I have gotten the LPS fab manual tensioner, clutch on(once it arrives from the UK) 6 speed gearbox on and ready for the Easter break, to go in!
    Break the engine in ->1,000kms and then yeah, ready to move onto the big turbo stage
    Having the tubular manifold ceramic coated black, should be good. Still have to pick a turbo - wastegate. financially this will be done later lol, the other car has consumed my spending account.
    Should be superb. Oh and I replaced my passenger side door lock, that was cactus. Tried filming a video and the GoPro had gotten too hot and stupid me didn't check it, so I've got half a tut on how to do that HAHAHA, another day!

    Once that's all done; should have the Maserati engine to work on; as I get all the refurbished parts back from the engine shop. Turbos too. Should be awesome...

    Long read but, lots done! Hope I didn't miss much; it will all come to me
    Last edited by JTop; 24-04-2022 at 08:00 PM. Reason: PHOTOS FAILING???

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