mk3 golf tdi into a polo 6n (with pics)

[DUB IT UP]

hello to all im new to this site, after reading some of the responces i know i'll get the help i need on here.

i need advise on a engine conversion i want to do on my 6n polo the out side been done to my liking, but it runs a 1.9 N/A diesel (AEF) which is real slow, and i want to put a TDi from the mk3 golf into it but am stuck on what one to get(which code as i will most likley buy the donar car and rebuild the engine and if it will fit, also how to get around aspects of imobilizers, if any ones done a similar conversion pls help as i need all the help i can get at the moment, thanks all

Manny here's some pics of my polo hope you enjoy all comments welcome

[MikkiJayne]

Love the colour!  

1Zs (up to 96) are common as muck and very cheap on ebay (£2-300 complete), but they are limited on tunability as the pistons are weak - 140hp max I'm told.

AHUs (96-98 ) are quite rare and more expensive but stronger and worth the money if you can find one. They can go to 200hp with the right turbo.

You can keep the immobiliser if you want to - its very simple electrically, and is a nice security feature. The transponder is very small and would probably fit a Polo key, or you could get a mk3 Golf key cut to suit your Polo locks.
If you want to get rid of the immo then the easiest way is to source an ECU from an early Audi 80 with the 1Z engine. They are electrically the same as the Golf 1Z and AHU, just with no immobiliser.

Are you changing the gearbox too? I think the 6N Polo diesel has a variant of the 085 gearbox from the mk2 and mk3 (86C), and I don't know how much torque this can take. You might be better off fitting the TDI box and driveshafts? You'd need the TDI shifter as the TDI is cable shift but that should be a simple bolt in.
(I'll have your old box if you do change it as I want one for a project!)

Oh, and I have the mk3 wiring diagrams when you need them.

My Corrado goes better with the standard 90hp TDI than it did with the 16V, so the Polo should fly! Especially when you start tuning it  

Looking forward to seeing this  :wink:

[DUB IT UP]

thanks for the help i most likely get a 1z as you say there cheap and i only want around 120 -130 bhp as a max, if i need the box and shafts then yea well sort something out on my old unit which is already recon'd.

what turbo should i use, i was thinking bout getting the original reconditioned as wellas the fuel pump, do you have any recomendations i live in the essex area. thanks again

manny

[zaprzal]

1Zs (up to 96) are common as muck and very cheap on ebay (£2-300 complete), but they are limited on tunability as the pistons are weak - 140hp max I'm told.

that's not true. I know some 1Z whichs had 170-180 hp and everything is ok...

i only want around 120 -130 bhp as a max,

if you need only 120-130hp you can try to make your NA turbo  

[DUB IT UP]

if you need only 120-130hp you can try to make your NA turbo  

to turbo my old unit would'nt be a bad idea as its only done 67k but i will have to drop the comp ratio also won't i have to still but an engine to use the best bits from i.e turbo manifold and intercooler etc.... im only asking as i've never converted a diesel into a turbo but i've done a petrol (my brothers vr6 which is now an animal) but if you know the 'how to' then pls help. thanks

[MikkiJayne]

 I know some 1Z whichs had 170-180 hp and everything is ok...

   I was told by a couple of people that the 1Z has weak pistons and tends to break above 140. Mine's broken at 90 though, so I don't have much of an argument  

[jtanguay]

well i'm shooting for around 150 hp so i hope these pistons can take it...

maybe their EGT's were too high? melted the pistons??? but that is normal on any diesel...

[DUB IT UP]

BUMP

[DA-BRT]

I've bought a 6N about 6months ago. Tuned up the AEF engine and now it's running smooth.

The planning is to get the ARL TDI (convert to M-TDI) in this summer. Problems for the 6N are:
- The very weak 085 transmission
- Engine is leaning to the front instead of rearwards in the Mk3 golf and others.
- Small driveshafts
- Engine and transmission supports have to be handmade.

A friend gave me a complete nose from a 6N and I already got the TDI with a ASD TDI 02A transmission.

I want to get started on the new supports in a couple of weeks. I'm going to put the engine and transmission in the same position as they are in the MK1/2/3 Golf. Or else I have problems with my driveshafts.

The driveshafts has to be hand made due to the length. I'm going to fit Mk2 golf G60 uprights and brakes in the front.

The shifter unit has to be replaced by one from a 02A transmission.

Exhaust and turbo got enough clearance in the back of the engine.

FMIC can be placed easily in the bumper.

[MikkiJayne]

Surely you can just use the mounts and driveshafts from a Polo Classic (saloon)? They had the big block 1.6 with 020 transmission, but still mounted to the chassis rails like the 6N - I found one in a scrap yard the other day. Didn't later 6Ns have this setup too?

Mikki x

[DA-BRT]

The complete nose from the 6n hatchback is different from the the Polo Salloon, Variant, Caddy Seat Ibiza, Cordoba, Vario.

The only one that's the same is de Skoda Pickup and Felicia.

Just have a look at the front fenders from the Hatch back and all the others.  :wink:

Can't use the supports from those cars. I already tried.

I got some supports from: Audi TT 20vT, Golf 4 TDI and I'm going to have a look if I can fit them.

[the caveman]

Man i'm sssooo pissed that vw never brought the polo and lupo to N.A. or at least Canada.  A few years ago someone i worked with's brother was testing a lupo for the DOT so my hopes were up , but no go. DAMN!
So for all you oversea-ers, sorry we can't answer many of your platform questions.

[DA-BRT]

I was wondering if they were sold on the other side.

Do you think it's a big problem to get 1 piece on the road there? Then you got realy something special. (or just drive it on an European licence... )

[MikkiJayne]

The complete nose from the 6n hatchback is different from the the Polo Salloon, Variant, Caddy Seat Ibiza, Cordoba, Vario.

Damn! You're right - I went back to the yard today and it uses a subframe like the mk2 Golf. I was confusing it with another 6N in the same colour in the same yard  :oops:

[DA-BRT]

Yes, Thats the problem to solve.  :wink: