"To Build a G60 16V"

1. Block

2. Head

3. Sparkplugs

4. Supercharger

5. Intake manifold

6. Alternator

7. Wiring

8. Blabber

9. Tech/Performance Data

1. BLOCK

To start you require either a 16V "PL" or "KR" block. Pistons must

be 027107065AVWM, piston rings 026198151A.

2. HEAD

Kick out old cams and valves and replace them as follows:

Intake cam 027109021AH

Outlet cam 027109022AH

Intake Valves 027109601C

Outlet Valves 027109611C

3. Sparkplugs

Plugs for this engine can only be obtained from VW Motorsport:

BOSCH FTDC 191000003

4. SUPERCHARGER

Attach the G-Charger to the block by means of the bracket

037145491A. Use the angled pipe 191145755B and the appropriate

hose to connect (they missed something here) to the intercooler.

Use a big of an intercooler as possible - DUUUH!

Install the potentiometer-pipe (whatever that may be, maybe the

airflow pipe?) 191145834VWM with appropriate small parts from the

enclosed list.

5. INTAKE

Bolt lower intake runners 027133202FSP to the head (don't forget

the gasket).

Before that insert injectors 028015092A with OEM G60 spec fittings

into the runner piece. Connect the injecotrs to fuel line V037711231.

Bolt on the upper intake (manifold, I guess).

Prolong the intake stud with the 90 degree angle piece and bolt the

G60 throttle body up.

Wastegate attaches by means of bypasspipe 191145826VWM to the

crankcase ventilation and the ISV, then to the charger.

6. ALTERNATOR

Use brackets V03771235, V03771530, V03771234 and 036903160VWM

to bolt the alternator up to the rear (what the fuck?!) of the

engine. Pulley 0337903119VWM hooks up to the alt. Supercharger,

waterpump and alt are driven by poly-V-belt 037145933SP by the

crankshaft.

7. WIRING (goodie)

The entire G60 wiring loom should be installed. Control modules

for full throttle switches, oxygen sniffer and knock sensor

are also taken from the G60 (donor car?).

It is strongly encouraged to install an ECU with a G60 16V eprom

which itself should be individually made for the motor.

Hook up wiring loom OEM style.

8. FINAL COMMENTS

This bulletin gives very rudimentary instructions only. Please

consult (not here) the attached list for small parts which

are reqired.

The engine can be built to run with a catalytic converter, in

this case use the G60 downpipe and cat. Should the engine be

built without a cat you must use a pre-heated oxygen sensor to

prevent faulty information of being delivered to the ECU.

Final adjustments are to be made with detached crankcase vent,

timing must be adjusted with blue temp sender detached.

Adjustment data to be taken form G60 engines.

9. TECH DATA

1.8l

9,0 : 1 compression ratio

153kW (208hp) @ 6400 rpm

247Nm torque @ 5000 rpm

Vmax 227 km/h

0,56 bar boost

cams: 9,6mm lift

coated piston floors