2008cc 8.75:1 CR 3A G60 build.

Darren at Gwerks informs me it's quiet normal for the G60 engine have the tubular manifolds glow red when setting up the timing plus with no air flow it's like an oven in the engine bay. Just wait till all you boys get your turbos installed. We'll be seeing some rather warm exhaust manifolds then.

EGT probe is a god send, thank god I fitted it.

Some more images I took before the oil pressure issue.


So here is the golf G60 big rad that fit's nicely behind the golf G60 FMIC, infact it's made to fit behind it. The old rad is only about as wide as the cowl as many of you are aware.

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Next I offered it up to the car front member and punched/dented a new hole for the rad to sit in. I don't like doing stuff like this to my car but needs must. Not much fun swinging a lump hammer millimeters from your supercharger either. The rawl plugs you can see in the other holes where used to hold a bracket which in turn held the old rad as it wouldn't sit on the front corrado member
with the FMIC.

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Next I attached the Intercooler to the rad with some minor modification to one rad boss, pattern parts hey.

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When I offer the whole assembly up to the car I discovered the hole I reluctantly bashed to the front member was about 2 inches out. so had to make another.

Ahhhhhhhahahhahahahhahah It only bloody well works.

Just had the final push today to get the car back on 4 wheels and moving and it drives really well considering it's new engine.

Did about 30 miles on country lanes just on and off the throttle between 2-3k to start but had it up to 4k as it felt it was happy to be up there. Lots of 2nd and 3rd gear acceleration and engine breaking to get the rings fluttering. Temps seem good too but it's defiantly lean.

Here some pictures from the final day.


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Car finally in one piece and on all fours.
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Car ready to roll just needed to get a shower, cup of tea and a cheese butty!
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Car after it's trip out bit of a coolant leak but nothing major will sort that out in the week.
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Car ready to roll just needed to get a shower, cup of tea and a cheese butty!

How can you think of food now? lol

don't 4get your cap and driving gloves.


edit:

Blimey those Golf FMIC are Huge.
Let us know how the cruise goes.
:salute:

dirtytorque wrote:Blimey those Golf FMIC are Huge.

I was just thinking that.

Looks good.

Toad wrote:

dirtytorque wrote:Blimey those Golf FMIC are Huge.

I was just thinking that.

Looks good.

Funnily enough so did I when I saw the photo on my computer. The Rallye ones fill the entire front of the car infact you have to mod the towing eye beam to get it to fit!!

Engine feels good, feels like it wants to rev or is that me wanting to rev it. Doesn't feel sluggish to rev due to the longer crank! Infact you have to keep an eye on the revs as it spins up real quick. Doesn't feel like it's lost any refinement over the original engine which isn't saying much but at least it isn't shaking the car to bits with the shorter rods.

ctwg60 wrote:

Toad wrote:

dirtytorque wrote:Blimey those Golf FMIC are Huge.

I was just thinking that.

Looks good.

Funnily enough so did I when I saw the photo on my computer. The Rallye ones fill the entire front of the car infact you have to mod the towing eye beam to get it to fit!!

Engine feels good, feels like it wants to rev or is that me wanting to rev it. Doesn't feel sluggish to rev due to the longer crank! Infact you have to keep an eye on the revs as it spins up real quick. Doesn't feel like it's lost any refinement over the original engine which isn't saying much but at least it isn't shaking the car to bits with the shorter rods.

Man it must be killing you,babying it.
I'd go nuts.
Did you just potter around town?
The shorter rods would make it more revvy eh?!!

No I didn't baby it I gave it more than half throttle up to 4k in 2nd and 3rd wanted to be as hard on it as I dare without damaging a ring. It's funny you sort of realise what your supposed to do once you start bedding it in and driving around in 4th and 5th aren't going to do it any favours. I was on and off the throttle as much as possible and used the engine to brake the car as much as I could.

I'm not sure the rods would make it more revy but there is less weight in the pistons and rods and it was anally balanced by the Engine builder. Even the clutch pressure plate was balanced. So......

The initial impression is that the engine is happy and not struggling too much with fueling or the fact that it is new so I'm happy, infact I'm just happy the car moves again.

You know what it's like when you change something on an engine it takes time to evaluate where the differences are on the road.

Just really pleased it works up to now.

Excellent work dude, that's awesome.

So it just wants to rev hey? I'd imagine the fact you have less weight spinning round will do that, along with the balancing. What type of charger tune do have you got on there?

mrbeige wrote:Excellent work dude, that's awesome.

So it just wants to rev hey? I'd imagine the fact you have less weight spinning round will do that, along with the balancing. What type of charger tune do have you got on there?

Tks mate, Charger is a new VW item with 10k on it, no porting just a 65mm pulley. With regard to the engine revving I was expecting it to be a lot tighter and needing a lot more working in to get it feeling as free reving as it currently does. Need to drive it more before I can give a better idea of what a 92.8 crank feels like over a 86.4mm as this was one of my major concerns with the larger capacity bottom end. At the moment it doesn't feel like it has a longer stroke but this opinion might change over time.

I've now done 150 miles with the new engine and I have to say I'm very pleased with it. It hasn't lost anything in changing from an 86.4 mm to a 92.8 mm with a shorter rod ratio, the unlightened flywheel, crank and finely balanced bottom end are doing their job I think of keeping the engine smooth. It's got a bit of a growl now at certain revs/loads which is cool and the exhaust note is a bit deeper below 3k.
I've been giving it as much stick as I dare over the last few days and generally just been enjoying driving it.

It's definitely running lean as you might expect and isn't much good at fueling on the motorway due to the extra load at speed but it's certainly not slow during normal driving.

Got it booked in on the 28th for a RR remap at chipwizards who are renowned for doing a good job of mapping the G60 digi type engines.

I'll post figures and the dyno plots at the wheels as soon as it's mapped.

drum role......

Glad it's going well so far.

Is that Wayne @ chipwizards? If so, I've nothing but good words said about his mapping capabilities

Looking forward to see the results actually.

Yep wayne at chipwizards, he did the other two notorious 2ltr G60 engines of Henny's and Blue_Joe's. So a convenient level playing field for comparison of my engine to the others.

ctwg60 wrote:Yep wayne at chipwizards, he did the other two notorious 2ltr G60 engines of Henny's and Blue_Joe's. So a convenient level playing field for comparison of my engine to the others.

It'd be interesting to be able to compare the three realy. You're just running a standard charger as well, aren't you? I always thought that Sam's 2ltr was a bit disappointing given the massive amount of money he paid for his engine. I think I remember Shaggy getting nearly the same output as his at the Stealth RR day from his Corrado G60 with far fewer modifications....I think that put Sam's nose out of joint somewhat..

You gotta remember though mine is just 2.0ltr. There has been no deliberate lightening of reciprocal weight porting of the head and as you say charger. I'm running a G-Werks manifold schrick 268 asym. cam and 65mm ribbed pulley with a golf FMIC so it should make more torque but top end power (bhp) I doubt, will be anything special. If it makes 20lbft over the entire rev range I'll be happy with that for now.

Currently it it very smooth on the roads and feels like it could loose a bit of weight off the flywheel but I don't want to affect it's road manners too much.

We shall see.

By the way blue joes engine was recently remapped by the new owner with a standard charger on a 65mm ribbed pulley and made 267lbft 4400rpm at chipwizards and 257 bhp at 6k at the flywheel that is.

The owner has complained pinking during road use, of terrible belt slip and the destruction of yet another clutch friction plate centre as well so you can draw your own conclusions......

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That's rather interesting reading...

I know when Sam first fitted it he had too small an exhaust on it, and was surprised when it melted the front silencer, and I also remember him being a bit stroppy at that RR day.

I've also heard a few good things about Wayne. How many miles do you want on the car before it's mapped?

^^^ haha thats because my 1.8 g60 only made 5bhp less than his.. i think anyone would be gutted lol

That 2L of his has always had issues from day one

As many miles as possible really hence the 28th as the day of reckoning. Don't think I could wait any longer. Out of interest shaggy (mike?) what did yours make and what was the spec? Maybe waynes RR is flattering!!

BJ's engine, when it was in his car, made something like 245lbft and 250bhp when it was mapped at wayne's and now 267lbft seems like a lot.

You know Sam's engine was initially meant to be 2008 cc but one of the original pistons broke and screwed the bore and that's when it became 2031 cc.

I think the extreme's of this engine, flat planed crank 83.5mm bore etc are at the root of the problems this new guy's having.

Yeh its Mike lol

It made 252bhp with about 220lbs of torque.

1.8 bottom end
big valve head
Shrick Cam
Boost return
Full blend charger
65mm toothed pullies
Red top Injectors
PSD custom live mapping session
Water Injection

Thats pretty much it really. Still miss that car

Impressive figures from a humble g60.
Don't spose you still have your power plot Mike ?

i think it maybe tucked away somewhere in my old build thread.

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Shaggy wrote:^^^ haha thats because my 1.8 g60 only made 5bhp less than his.. i think anyone would be gutted lol

That 2L of his has always had issues from day one

One thing I would say though Mike is that his car had a fair bit more useable torque through out the rev range.
lets not fget it is torque that accelerates a car.
Not trying to belittle your achievement mate,but blue_joe torque curve is quite impressive.(Area under the curve n all that).At 2000 rpm he had about 200 ft lbs.

Shame the car was somewhat unreliable.

Yeh thats very true.. Torque is the key with G60s...

I am sure that Sams would have easily been the quicker car over mine if we had a head to head... I remember seeing his efforts at GTI international... he just couldnt put the power down with it... looked like a bit of an animal to get of the line.

But yeh, as you say shame the setup is a bit unreliable as a package... i cant imagine how much wedge has been chucked at that engine between sam and the new owner..

I can vouch for shaggys old rado shifting, mine was similar spec but never dyno'd it but power was everywhere in the rev range