UK-POLOS.NET - THE VW Polo Forum

hey guys and girls

thought i'd give you an update of how i am getting on with my G40!

i have been using her for the past week to travel to and from work and college. i love the power and i think i gave a 4x4 driver a bit of a suprise!.

as the insurance for the g40 has now ran out (only insured for a week to get her home), she has gone up the back of the drive for some TLC!

i ordered some parts to carry out a service on her which included a new dipstick, drive belts and cam belt, clutch cable and of course oil filter! (ordering K&N pannel filter today) a total of £100+.

i have fitted the dipstick as the clips had broken of the old one. i've also removed the back GT and catalyst badges and put on a standard black polo badge. removed the rear speakers for inspection of wiring. also fitted clear indicators which i had lying around!

as for polishing and cleaning, i gave one wing a quick once over with some colour restorer and then with some polish and it has come up really nicely! the wing is no longer pink but a lovely deep bright red! also given one of the wheels a quick clean and they come up really well as well!

looking forward to giving her a full polish and then engine a complete service while the charger is away for servicing!

all in all, the project is coming on really well and will look real nice when she comes back on the road!


regards
Doug

just thought I'd give you an update on how my g40 is going!

I've now sorted out all the wiring from the old alarm (removal), the old tow bar wiring (removal), and radio (removal of bad wiring).
fitted a K&N panel filter
fitted new dipstick
fitted clear indicators with silver indicator bulbs
removed all original speakers
straightened all wipers and fixed rear wash wipe
removal gt badge off rear and fitted standard polo badge (sprayed black)
removed catalyst badge off rear
fitted debadged grill

waiting to go on the car are:
oil filter + oil
black mesh for lower grill
rocker cover gasket
cam belt + water pump seal
drive belts
clutch cable
new speaker cable
half smoked rear lights.

I've also started polishing some of the panels and the paint really comes up well!

there is also a chance the charger isn't what is making the noise on start up, me and my dad believe it to be the cam belt being a little loose! this would save me a bit of money and I could go straight to a full blend next year!

also going to replace the water pump while the cam belt is off. it looks like the teeth on the water pump are a bit worn, so while we have the cam belt off, its worth us taking the pump off and putting a new one on.

still plenty to do but I have made a great start!

comments??

regards
Doug

doug&dan wrote:just thought I'd give you an update on how my g40 is going!

<snip>

still plenty to do but I have made a great start!

comments??

regards
Doug

Pictures? Before and after?

hopefully i will have some soon! i have been taking pictures as i go, but my computer is screwed up so i can't get to post them on here! as soon as i can, they'll be on here!

can't wait to get her fully up and running! then we'll see wot the nova crew have to say!!

Yes, pictures are always needed.

Personally the first thing I would do on a G40 is get the charger overhauled. You are better being safe in the knowledge it's in good order. Sounds like your getting it well sorted, you might be better off getting a new water pump too.

A must have for any g40 if you plan on tuning it, new fuel pump, g60 injectors and sns chip. Just to make sure its fuelling right

G60 injectors and SNS chip aren't really necessary straight away - a set of stock replacement G40 injectors would be enough, or getting the originals tested and cleaned.

I found ECP to be the cheapest place for the replacement fuel pumps, they also list injectors too... But I went for the G60 greens, and SNS - but that's coz I've got 1341cc and planning a lot more work.

the car runs sweet as a nut so i won't bother changing the injectors and fuel pump yet! also i know a new VAG fuel pump runs off at around £170 i think! and my funds are running a bit low! roll on payday!!

as my computer is messing around sooo much, i can't post any pictures up at this time, but i have been taking pictures as i go along!

as soon as my computer is sorted, i will post up some pictures for all to see! at the moment, they are mostly of the dodgy wiring!

I got a new lift pump, new inline pump and new fuel filter for just under £150 from ECP all together. Genuine VDO lift pump, and genuine Bosch inline pump. Injectors are about £130ish if I remember correctly.

That might seem expensive, but take it from someone that's been there, a £1700 engine rebuild bill is more expensive...

hey everyone

major work has been carried out on the G40 today! the CAM BELT!

as i said a while ago, there appeared to be a noise coming from the charger area! further investigation and it seemed that the noise was actually coming from the cam belt, which was on my list of things to do!

so today was the day we started having a go at the cambelt! as the first cover came off, you could see that the belt had been rubbing on the cover


Note the two lines on the side, this is where it was rubbing

also, on the outside of this cover, marks can be seen where the drive belts have been rubbing on the cover:






then, looking at the belt, i think we caught this just in time if you ask me!







7 teeth missing in total and as can be seen from the last picture, several more would have been coming off very soon!

then we come to the bottom cam belt cover, do i need to say anything??





we reckon the lower cam cover had come loose at some point in its life! lucky this was on my plan of things to do!

regards
Doug

looks like you been very lucky with the belts,how much would it have cost to rebuild the G's engine if that belt went snap at 70 mph?

Erk.. looks like my cam belt cover did after the guide ring on the water pump snapped off. The state of that belt is scary.. did it feel like it had an ever so slightly lumpy idle before you changed it? Because when my belt split half way across, the only reason I thought to look under there was that I could feel a very slight regular 'lump' in the idle, I guess as the split section passed over one of the sprockets. Would have thought yours was all over the place!

Holy s**t!

Glad that you caught that in time, could've been nasty. Shows that it pays to regularly check the cambelt condition, especially on a car you've just bought.

You are very lucky, that it hadn't snapped already !

i no i am very lucky! think i may be checking the Cam belt on my blue one very very shortly!

the car was running fine with no problems, the only thing i noticed was a very very slight rev drop every 10 seconds or so. but it was very slight!

while we had the belts of i was able to inspect the charger for any rumbling or play in the shaft! but everything seems all good!

obviously i would like to get the charger rebuilt, but at the moment, i am running out of funds. i am planning on going the whole hog next year and getting a full blend rebuild once a change to an insurancce company that understands wot i am going on about!

regards
Doug