The G60 discussion thread!

[clipperjay]

Full-Range Programming: The only truly full-range programming in the industry, AutoThority provides refinement and drive-ability second to none. Your car feels smoother, quicker, and more exciting under all conditions.

‘Soft’ Rev-limiter: AutoThority typically raises the factory rev-limiter slightly to extend the engine’s operating range. Mainly intended for track and auto-cross use, as a way to ‘hold a gear’ during a curve, etc. our exclusive ‘soft’ rev-limiter offers better feel than stock and is much healthier for the engine.

We are often asked why our E-Proms out perform the factory's and additionally why they out perform our competition. A Bosch Motronic E-Prom contains ignition timing and fuel injection metering information located on two three-dimensional maps. The factory has to tune for the lowest common denominators of these two factors and therefore leaves a certain amount of room for improvement. By assuming a high grade of fuel (92 octane minimum) and a good state of tune, we are able to modify these maps to optimize power and torque as well as throttle response and overall drivability. We distinguish ourselves from our competition through our exclusive Graphics Tuning Software package which allows us to retune the entire operating range of the engine. The full throttle map reflects the engine's tuning when "the pedal is to the metal". It is the place every tuner modifies and the place where we spend the least amount of time. The part throttle realm on the other hand, is the place where you spend the vast majority of your driving and is where we concentrate the most time and effort to re-map. The idle mapping we leave alone so that tune-up and maintenance remain identical to stock.

Nick what variables do you look at when it comes down to air temperature or is it just within a set range?
what system do you use when remapp or is it pure ecu sensor feed back?

[Charged]

I'm Considering a 68mm pulley as most of the euro boys say for short runs on 1.1 bar of boost the 68mm copes well and saves the charger meaning service of about 25,000miles if you go beyond that like a 65mm then your charger might last 10,000miles depending upon how you drive? If on the motorway doing 4000rpm+ 71-68mm pulleys are better for the whole engine as a daily. If you drive short distances, weekends, rev high and stop start 65mm is fine.
I still think if I had the cash that a 2.0ltr block would cope better and use the extra boost without detonation or stress on 1bar! 
 

Do you mean bore out the G60 engine to 2L or just fit a 2L bottom end from a later model? Reason I ask is because i've heard that the G60 Rallye engine is one of the strongest engines VW has made so it wouldn't be beneficial to fit a 2L from a weaker engine. Am I correct in saying this?  If I wanted to how much am I looking at to get mine bored out to 2L including uprated pistons etc?


Also another question about the crossflow head. I've just bought a 2003 Beetle 2L engine with the crossflow head, do I just need to change the head or will i need the distributor and any other bits from the Beetle engine to get it fitted ok? Also do I need a custom gasket for this?  Where's best to go to get my head gas-flowed, ported and polished as i'm gonna do this before I do the exchange?.. 

Again, thanks in advance 

[clipperjay]

Do you mean bore out the G60 engine to 2L or just fit a 2L bottom end from a later model? Reason I ask is because i've heard that the G60 Rallye engine is one of the strongest engines VW has made so it wouldn't be beneficial to fit a 2L from a weaker engine. Am I correct in saying this?  If I wanted to how much am I looking at to get mine bored out to 2L including uprated pistons etc?


Also another question about the crossflow head. I've just bought a 2003 Beetle 2L engine with the crossflow head, do I just need to change the head or will i need the distributor and any other bits from the Beetle engine to get it fitted ok? Also do I need a custom gasket for this?  Where's best to go to get my head gas-flowed, ported and polished as i'm gonna do this before I do the exchange?.. 

Again, thanks in advance 

Well I meant the Rallye block is good, but still the thickness of those block walls still need a margin for stress so would love to bore out to 2.0ltre, but 1.9 is realistic and replace with Rossniers or JE or forged KR piston sets, cost wise Germany for about 350-450 notes for a set. Then valves, guides, cams, flywheels and sumps the usual sundries another £500.00. The labour is what kills us as companies who use CNC precision machines can minimise the hairline fractures on the porting by adding the required pressure/load to shave those vital bits of metal down to the last micron. I guess if your motor is in good nick they can re-use most bits, but like I said if money was no object I would just get a whole block from low miles (PG 16V off a limted) and rebuild with the fore mentioned specs. Hence VR conversion are popular, but a well sorted 8v or 16v lump will be better on fuel and reliability some will say even faster if balanced correctly as they weigh less than a VR6 block.

Miss conception about ported heads does not require bigger gaskets as the block stays the same dimentions outside internally is where the changes happen. Well with all types of modifcation to get the best out of it and running well your gonna need timming and fuelling issues sorted out with remapps and bigger injectors to get over the 250BHP barrier. I would not consider spanking money unless I had about 1.5K in the bank to spend on a block mods.

Pm if you need quality chaps who do this every day they are better advised than I for your personal set ups?

Jay

   

[Organisys]

Ok, lets talk about gear ratios and LSDs. The first and second ratios in a G60 are just plain daft. Whats the crack with using a VR6 box to swap 1st and 2nd over?

[clipperjay]

Ok, lets talk about gear ratios and LSDs. The first and second ratios in a G60 are just plain daft. Whats the crack with using a VR6 box to swap 1st and 2nd over?

Well all I know is the people who run VR6 cogs with the final drive will make the rev band longer between change ups. This might mean faster speed per ratio, but on the final gear it will bottom out just like your G60 box would.
The input shaft 1st and second is proberly what your looking for to imrove the short 2nd.But like I said the input shaft as one unit might be better or easier to swap out on your running gear. The tools involved to get exactly what you want i.e a hybrid G60/Vr6 would be painfull to get right as you can imagine. Some companies offer this service with tried and tested ratios and yes not cheap fella approx over £1000 for custom LSD rebuilds.
What kind of speeds are you hitting in second?

Jay

[Organisys]

Pricey! for a rebuild with a £400 ish LSD as well then.

Yeah the second is way too short. By the time you have wheels spin under control it is time to shift up! lol. not sure of exact speeds as clock is in kph and I'm concentrating on not hitting the limitier!

 

[clipperjay]

Pricey! for a rebuild with a £400 ish LSD as well then.

Yeah the second is way too short. By the time you have wheels spin under control it is time to shift up! lol. not sure of exact speeds as clock is in kph and I'm concentrating on not hitting the limitier!

 

Some chaps are running cogs from the TDI's apperently much longer ratio than the VR6? Also cheaper!
Part numbers, but I haven't done this mod yet myself I might if it goes well on yours matey.
Not bad money and the change out can be done bellow without box pull out.
The benifits are known more for crusin in 5th gear. 

02A 311 361 M £59.80
02A 311 158 R £94.21

[gibby]

I've got an Autothority chip on mine and I can reach just under 100kpm (about 60 mph) in second gear before hitting the limiter.

[Dolly]

after very serious consideration i have decided id like to G60 my mk2 1990 8 gti, after searching i found it inconclusive what was needed for a complete swop.

Now if i get an engine with charger and intake all attached, Gearbox attached and wiring looms what else is needed?

stuff i think may be required: Driveshafts, Hubs, Radiator, Fan, Cooling system, clutch cable, accelerator cable, steering rack. steering coloum and dials?

is there anything on my current 1990 8v engine (PB) that can be used ie, intake manifold exhaust manifold.. anything really. thanks

[clipperjay]

after very serious consideration i have decided id like to G60 my mk2 1990 8 gti, after searching i found it inconclusive what was needed for a complete swop.

Now if i get an engine with charger and intake all attached, Gearbox attached and wiring looms what else is needed?

stuff i think may be required: Driveshafts, Hubs, Radiator, Fan, Cooling system, clutch cable, accelerator cable, steering rack. steering coloum and dials?

is there anything on my current 1990 8v engine (PB) that can be used ie, intake manifold exhaust manifold.. anything really. thanks

It might be cheaper to find a G60 lump, ECU with charger brackets than go down the BBM route?
Jay