Traded for this last summer. Put ~$3k more in parts alone into the engine/lysholm setup.
Rescued it from the previous owner.
Now it is configured correctly and runs great on Megasquirt standalone.
I did all of the work and I have a lot of receipts.
I've improved a few things that the BBM 16v integration "kit" doesn't address.
Boosts up to ~17 psi, no leaks, no belt slip.
Fueling is spot on and the Megasquirt works great.
No idea about dyno numbers, haven't done it. The car does rip though.
It's a blast to drive but now the project/build is done. I would like to put an oil cooler, water/meth, and a cage in it but, but that's even more money that I'll never get back out of it. I'm trying to get out of VW's and I want a bike.
And no, I'm not parting it out.
Cash is king.
16v 2.0 9A.
G60 to custom Megasquirt harness
Rebuilt bottom end and head. Holds 20 inHg at idle, 24-26 inHg on hard decel.
Wiseco forged pistons w/ rings and wristpins, 9:1 82.5mm (9/15)
ARP head studs
9:1 head spacer (makes effective CR ~8:1)
*Can confirm the stock head was rebuilt: new valves, guides, and stem seals (9/15)
New water pump and coolant hoses
New timing belt and tensioner
New oil cooler flange gasket
New sealant on distributor block off and crankcase breather
BBM crankcase breather with seal and barbed fitting
New beetle oil cap/valve cover breather
New Moroso catch can w/ custom braided stainless -10 lines, black fittings
Doweled crank gear (2 dowels)
16v distributor and hall sendor
Autotech adjustable timing gear
Bored out G60 throttle w/ dump
Scirocco 16v intake manifold
New 42lb Bosch green top injectors
New injector cups
BBM billet fuel rail
Holly adjustable FPR
Press fit feed line with a/n fitting for rail
Aeromotive fuel pressure gauge. (pressure is set to ~3bar)
CIS fuel pumps
MSD Blaster coil. Direct fired from Megasquirt
Autotech plug wires
BKR6E plugs...7E's were preigniting
New idle screw and seal from BBM. ($80 fricken idle screw. wtf)
New factory ECT sensor
AEM wideband controller/digital gauge w/ new probe
VDO vac/boost gauge
New Autometer digital oil pressure gauge
Idle air valve and cold start injector deleted
NLS cold start plate w/ vac port
A/c a power steering deleted. PS pump is still bolted up, just not running the vbelt between it and the crank. I have the pulleys.
2.5" catback exhaust, borla muffler.
2.0 manifold and ABA downpipe
Runs synthetic 20w50 racing oil (higher Zn and P levels).
Ave. oil pressure at idle, at temperature, is 30-35psi after rebuild.
On an 85 deg day the oil temp after pulling at full boost through the gears was only 217 deg F via the MFA. So it does not run abnormally hot. NA VR's can run hotter than that. Oil temps in cruise are around 200-210 now that it's hot out. Coolant temps are around 200 deg F fully warm validated via TunerStudio. So it operates well within reason.
BBM water flange
Godspeed Corrado radiator
Tig'd return flange
High speed slim fans
Spaced ABA water pump pulley
MkIV crank pulley with custom CNC'd aluminum spacer
6 rib, ~80" serpentine belt. It's a Corvette belt
G60 accessory bracket w/ studs
BBM alternator relocation brackets
BBM tensioner bracket
BBM tensioner pulley bracket
G60 belt tensioner w/ BBM adjustable tensioner cap
Subaru idler pulley mounted to the G60 accessory bracket to provide deflection between the alternator and blower pulley.
Gruvenparts G60 tensioner pulley
Gruvenparts ABA idler pulley. Drilled the center out to m10 1.5 pitch with a grade 8 bolt.
The hole in the G60 bracket matches and has a nut on the inside. Much more stout than the factory m8 bolt.
This is a weak point I've found in the relocated alternator and lysholm setup due to the tension needed in the belt. Not anymore.
SR2-2087 Opcon Lysholm supercharger.
50mm pulley. Extended drive for 16v serpentine belt conversion.
Will come with hardware to integrate the blower onto an ABA as well, extra BBM braided feed line too.
BBM braided oil feed line. Runs off a flange adapter on top of the oil cooler. Stock sensors retained.
Oil return line runs to a barbed fitting welded into the front of the oil pan.
42 Draft Design block and press fit hose for sensor relocation. Oil pressure sender and stock low pressure sensor runs off of it.
I drilled out the m8 holes in the G60 accessory bracket and the BBM mounting flange to m10 allen heads. The previous owner had either cross threaded or rounded all four out.
ABD FMIC with BBM G60 piping and some custom bends
Silicone couplers and reducers w/ t-bolt and some ABA constant tension clamps
Copper plated 3" pipe w/ 50mm flange, off of a friend's old supercharged VR.
HKS ssqv bov, black edition. Mainly a back up for the stock throttle dump.
Megasquirt 2 v3.57 Extra
Self tuned and wired.
3bar MAP sensor
Bosch BIP373 ignition driver
Speed Density fueling
No TPS used. Just running MAP based with MAP based acceleration enrichment as well.
Injectors are wired into 2 banks for better resolution at idle.
Cold and warm idle are actually very good. Vac does not oscillate.
TPS line from Megasquirt is grounded to reduce noise. TPS based accel enrichment is disabled.
Uses MAP based accel enrichment.
New Bosch knock sensor with KnockSense knock conditioner. Wired into Megasquirt to enable fuel/timing cut on knock detection.
Red LED knock indicator mounted in a dash switch blank.
Wideband signal is calibrated and feeds a reference signal to Megasquirt for EGO correction and VE Analyze Live. I rewrote part of the simple algorithm and look up table that came with the MS Tunerstudio application. Now the AEM reference signals are correctly converted for use with the target AFR table...so EGO correction and VE Analyze Live functions correctly.
Comes with serial to USB adapter for tuning.
G60 hydraulic clutch swap and brake master
New mkIII vr flex line
New slave cylinder
O2A swap with 228mm flywheel and clutch
OE 4 wheel disc brakes
Braided stainless flex lines
Corrado HD speedo cable
14x8 widened A2 steelies. Powder coated. G60 center caps.
Toyo Proxies. Slightly stretched.
FK Silverline coilovers
Poly control arm bushings
Stock front sway bar
28mm Autotech rear sway bar
Front and rear Autotech strut tower braces
1" rear axle spacers.
Big bumpers, tinted turns
Shaved banana lights and rear emblem
Single round badgeless grille, red trim
Green Hella Magics tail lamps
FK smoked cross hair headlamps, 5000K HIDs
OE fogs, 5000K HIDs.
Third brake lamp is deleted
It was resprayed before I got it but there are dings in it, and chips from being low that you'll see in person. It happens. It's a 21 year old shell, but is in really, really good shape I think. I get complements every time I drive it. The paint looks great. It's getting featured on Canibeat soon so there will be more pics. I'll post a link when it happens. (still in progress)
All grey Recaros. No rips, no cig burns - front or rear.
GTI floor mats
Stock GTI dash, 16v glovebox, and cluster
Gauges are in the center console
Grey, black, white, and red plaid headliner and recovered sun roof
Black parcel tray
Momo race steering wheel
Red LED strip in place of the stock cluster bulbs. Wired into rheostat.
Sony deck, Pioneer dual channel components, 600w Sony amp, 12" Eclipse sub
Price: $8000 obo.
I'm flexible within reason. I don't want any cars in trade. Cash, bike, or both.
I don't think that this is a bad price to start at. I don't care if VR turbo's are faster or cheaper, this is something that not a lot of people have. It was a challenging build, that's why I did it. I could have slapped a turbo on it and tuned it in half the time. Everyone I've seen with a relocated alternator on this application has belt slip and low boost. Not this one. Buy it.
PM me if needed.
Shot in late July:
Last edited by wolfsburg2617; 04-14-2013 at 08:45 PM.
Suggested viscosity and weight for a 16v. Plus it's what BBM suggests for the lysholm. It won't break down as fast I'm betting given the high amount of heat exchanged. This lysholm spins 3x what the crank does, so at 7k it'd be at 21k. Even as efficient as it is, lots o'heat generated. Fresh rebuilt 16v, sure you could go thinner. Not on this application though. Pm me for technical questions. Don't need this thread to be a mile long. Thanks.
still for sale. sent pm
adding an oil return line from the catch can to the oil pan this week. been tuning at full boost through all gears, getting tired of emptying it lol.
this is normal so nobody freak out or anything...oil has to go somewhere with all that crank case pressure.
still waiting on an opportunity to get more pics shot.