Dubberz

Garage => Shop Talk => Builds => Topic started by: Northendroid on Nov 17, 16, 18:20

Title: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Nov 17, 16, 18:20
Hi folks:

Some of the info has already been posted in another thread but I thought I'd start an engine build thread should someone like to try this hybrid build.

1991 Corrado PG block 1.8L 8V G60, little history car sat for four years ran but has an engine knock, oil light on, makes no power. Reading through previous owners paperwork two items come to light one is the car is bored to 83mm and the second is it went through a lot of head gaskets. Was going to rebuild the PG engine until I came across a brand new AEB block with crank and intermittent shaft installed. Was cheaper buying this block than it would have been to do the PG block re-work.
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FisGDJhh.jpg&hash=eef896249ee39cc5086338b2cda370d7)

Will be using stock 81mm pistons with new rings, stock conrods/new bearings bolt up to the AEB crank conrod journals:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2Fum2O9iq.jpg&hash=7647f8b49a787f3c9d121e22b6e0b5ff)

Here is a list of mods that need to be done to the block to work with the PG 8V head and G-Ladder:

Biggest mod is the rear support bracket of the G-Ladder requires a 5mm aluminum plate welded to it, machined to the shape of the crank vent port and a port tapped for a #10AN fitting which will be routed to the the G-Ladder return. This will supply additional lubrication to the supercharger.

Rear G-Ladder support bracket:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FxjrRerL.jpg&hash=a20cbf78ea9a08c69af7c3f135c41a15)
Thanks to Shawn Dezego

Modified to fit in the area:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F9IwY3Yd.jpg&hash=77a538d7cb654aa9987d463543e58146)


Knock Sensor Location:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F3ClxaqK.jpg&hash=bbea7d18ebae4c3ce937eb0e0e1cdcac)

Drill thru block and tap this existing bolt hole to accept the G-Ladder oil return
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F4EeHhRi.jpg&hash=e469651ccf8144192541dd89d3138b54)
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FTCROoHe.jpg&hash=f4b445481a78c5c1ff39cde2d5a20ee3)

Install a frost plug:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F0jUDL7b.jpg&hash=30c9669674e86f09af184675c16143a2)

Install crank position sensor (not used - only fills the hole):
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F1ccxo4z.jpg&hash=869c0e182b14a9df5df84bacb0092abf)
[(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FDe8HVxU.jpg&hash=623eafb1782a10febbbf6c149530933b)

An AEG head gasket is used with the stock 8V head, the three rear oil journals will be blocked when using this gasket:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FUIHHUsK.jpg&hash=5fe12239811d642babd276f536e03ed5)

Purchased BBM Stage 4 chipped ECU, 3.5 bar FPR, 268/260 cam, 65mm pulley
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FS9bM9Ht.jpg&hash=49dabc2eef83c5fe5027ea73c3838054)

The intermittent shaft gear is the same pitch as the PG distributor:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FcYJUxfQ.jpg&hash=adc718373695d93bebf55b18b8f29770)

The distributor and oil pump must match, PG distributor gear/oil pump have a slotted setup, while the AEB setup has a spline gear and oil pump:
PG distributor and oil pump shaft - slotted
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FdNJLTjx.jpg&hash=23c8d3b95b575d45912bc99aa59b58d6)
AEB Spline distributor oil pump - spline type
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FD1gmep8.jpg&hash=e4aaaf8f6359b2980db8ed49f5a83913)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Nov 23, 16, 18:51
The back of the rear G60 support bracket machined flat and a 5mm aluminum plate welded to the back of it:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F9CMpJZQ.jpg&hash=ce1777178911b81b9d7142f1ec03feb9)
Thanks to sdezego for photo!

Then it will fit like this, a hose is ran to the G-ladder return for additional oiling of the G60:
[(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FESOy4RC.jpg&hash=6214011c5b986ce27da459d8d94f5d14)
Thanks to sdezego for photo!
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Dec 06, 16, 16:15
Took the engine apart today to see why it was knocking

https://www.youtube.com/edit?o=U&video_id=0FBRKljurzo (https://www.youtube.com/edit?o=U&video_id=0FBRKljurzo)

Bearing is MIA:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FkIY041g.jpg&hash=c4c159f034a8778dabe11a72a4b8a137)

Crankshaft is toast, it also has a tight spot when spun:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FS4z1Hob.jpg&hash=5c016fa02294a8b40384c81489dd5c43)

Bearing from cylinder 2 & 1
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FG4xjHPV.jpg&hash=1beaf22a479b27435ff9c46dc2b5c868)
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F3PkERvp.jpg&hash=b9a922e4f1e1d51c6b8b7dd311bd9744)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jan 02, 17, 15:42
When I removed the oversize pistons from the PG block though that the bottom skirt had came in contact with the oil squirters but looking closer looks like they may have been ground at the JE before delivery. They are all ground the same and seems at the same angle as well
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FjA9xTds.jpg&hash=ce5d96a7bc2510d2aabe920d92cb1f4b)

[(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F7B8dPUn.jpg&hash=2eece1110a93cd2793dc846f1a3e18cb)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jan 08, 17, 15:39
Started cleaning the internals to be swapped into the brand new AEB block. Soak the pistons in Berryman Carburetor & Parts Cleaner for 24hrs carbon wiped right off, re-soaked for another 24hrs, all piston ring grooves are squeaky clean. Top of the piston not perfect but lot better then what I started with :)
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F700EKvR.jpg&hash=c58e4a321997418b9146f428c249dd26)
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2Ff9emUub.jpg&hash=db2182486bd277bbcd2e1e4b1e4f44e4)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Schmiesus on Feb 08, 17, 21:23
Nice work
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Feb 09, 17, 06:00
Thanks little slow going but still moving forward


Sent from my iPhone using Tapatalk
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Gerg on Feb 09, 17, 07:43
The parts cleaner is badass
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Feb 09, 17, 08:05
Yeah I'm really pleased with the cleaning it produces.


Sent from my iPhone using Tapatalk
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Mar 27, 17, 20:46
Found a MK1 TT AWU intake manifold for the 1.8L 20V G60 build. Guy also had the phenolic intake manifold transition spacer.

Will need blasting and repaint:
[(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FSRqmVpt.jpg&hash=ccbef319755d16f47b35911f0eaa975b)

Next item to find is a OBD-1 ABA throttle body.
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Mar 27, 17, 20:47
Bought an AWU intake manifold for my AEB 1.8L 20V G60 build, it came with phenolic transition gasket but was missing the small port metal gasket is #058129717D the correct part number?

Stripped:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FnHMlYFn.jpg&hash=acd35a4b7356ed61d72b817ca8d376bd)

Prepped:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FU6roSmC.jpg&hash=bcc0abe57c24cf7328e539c193cd87d4)

Baking in the Oven :laugh:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2Ft4fX2iJ.jpg&hash=519bf845246f65643d5dd6aae56a3a91)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on May 23, 17, 04:12
Not pleased on how it turned out, stripping it and starting over minus the wrinkle paint.
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F89HTlKX.jpg&hash=5ce64ac258eba11c9a9e8c71f7e48e35)

Picked these last tonight from an Ottawa VDubbing member, Eibach Pro-Kit for the Corrado.
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FcHKDOTM.jpg&hash=e29046cfaade7e4457781ec9b7a05ac8)

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2Fw2uxIBR.jpg&hash=55d6762a840d3b55c5cfd558fd7475c1)

MK4 shifter and shifter tower conversion kit that someone purchased but never got to install. Bit of cleaning and lubrication should be good to go. Perfect time to do this while the engine out.  :D

[(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F3XTCqMV.jpg&hash=74429a72e8578b50c6cbf0a6d3366167)

Got the timing pulley cleaned and painted, just need to do the same to the intermittent shaft pulley.
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FTTNLuLT.jpg&hash=c2bb793d01a5063200ee8dbcb0995516)

Got the BBM 268/260 camshaft changed out and the FPR. Also put the chipped ECU back in the car.
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FVULceNb.jpg&hash=812ce15782e562ee2fc46467f7c60200)

Buddy of mine offered me a set of 15" x 6" Sebrings at my favourite price (free LOL), I just got to get them from Edmonton to here though.
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FlBDAmng.jpg&hash=46c9d5ec967ad3b03d81264179834354)

Looking to do a custom lip to them:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2Fb9CBYO7.jpg&hash=bd00366011f4de9a6e8e9ea1955b33e6)
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FcmRQ6NE.jpg&hash=a74b372e25754478dcbce653a1dc1a55)
Also going to need center caps.

Picked up a second 02A tranny from a 16V Passat for the 20V. build, has a better gear ratio then the stock tranny. Bonus got a newer starter (which I needed) and another clutch with on 6,000 KM on it. The price was right but the drawback was it was an 16hrs road trip to go get it in Windsor, Ontario.

Picked up a 02A transmission out of a Passat 16V longer 5 gear
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FVouwwha.jpg&hash=235c28bcc202b81200d4bd777e621c8c)

Picked up  Neuspeed strut bar from OVD member VRT 
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F6L3GGj2.jpg&hash=34359406dbe0ef63cc4f8a8ad05ba328)

Parts came in today just waiting on piston ring gap tool  :D
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FM4Us3mA.jpg&hash=6b810fe7bda92f4de18d3c62ab1087a1)

Removed the intermittent shaft pulley from the PG block to test fit onto the AEB block, turn out that the PG pulley needs machining to add a keyway will since the intermittent of the AEB pulley has the keyway built into the pulley. All part of a hybrid build.
PG on the left - AEB on the right
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F62k0p6L.jpg&hash=24106ba4f83262823f81a2768fc43769)

Close up of the AEB pulley
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FPqJvyOJ.jpg&hash=d96510b101084f34810b48360304c332)

AEB intermittent shaft keyway is cut right thru the shaft.
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FhMMjibr.jpg&hash=60d8b9b4987127627fbb4c58d48c86fc)

Wheels on their way from Alberta to Ontario, co-worker on his way to NFLD and will drop them off on the way by.
[(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FfvXqXp7.jpg&hash=f82ff3db2714853120b4997e91785b40)

More parts arrived for the Corrado:
Prothane Bushing Kit (new still in box from Vortex Member)
Center Caps for the Sebring Wheels
Diesel Geek - MK4 Shifter, Side to Side Bushings, Side to Side Super Slider
Phenix Engineering - MK4 Shifter Bracket Bushings
Piston Ring Gap tool - Can start putting internals back together :D
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FiU09ln3.jpg&hash=f3088a6b4171affd38887687c9486e78)

Prepped and painted 02A shift tower and the shift cable support bracket, install new bushings, slider and tower shaft seal.

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F58cWloj.jpg&hash=a53e0d0a56c469bf947566993d0e97d9)

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FrU83FMa.jpg&hash=75127340687de4a5611d0d9b33c74a48)

More progress on the Rado.
Yesterday I built a ghetto engine lift out of 2 x4, 2 x6 with a 1 ton cable puller  :wtf:  to swap out the old PG block with the new AEB block on the engine stand, while I had the AEB block on the lift installed the flywheel and used my flywheel lock tool and got the AEB crank bolt loose.
Safely on the engine stand without hurting myself or others LOL!
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2Fg3Ujlm9.jpg&hash=140be330124d9af8d362e5682b0fe924)

Had a stripped allen bolt that holds the harmonic pulley/power steering pump pulley to the crank pulley, bolt the assmebly onto the AEB block, drove a torxs bit into it held back the crankshaft at the opposite end and was able to break away the bolt :beer:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2Fd88ilCJ.jpg&hash=41df76eba0c77267c19f843f3dc45559)

Installed the pistons into the AEB block:

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FQyPDxjS.jpg&hash=0e200b08d8c22f0136a22b4a35e8ac7a)

All went well till I got to piston#4, notice the rod bearing cap was fitting right when I snug up the bolts prior to checking bearing clearance. Remove the piston only to find the skirt on the opposite side of the oil squirters now has a chip broken off *banghead* .The PG block doesn't have an impulse wheel so I know need to remove the crankshaft, impulse wheel and re-install everything. I'll be looking for another stock 81mm PG piston and some new cap bolts as well. Another hiccup in the hybrid build :D

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FfHB1Aa3.jpg&hash=5c6289d01d267b625498b79f4b20c2f1)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on May 24, 17, 23:05
Ordered main bearing bolts. M10x65 Part# N10263801 and ARP conrod bolts.

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FRplxk8s.png&hash=748b27c561ad2a166020a2e5c8874dbb)

Will also need to get the big end of the conrod re-hone as per ARP instructions:

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FqQEdn80.png&hash=ad0c1cec3f0fe6264a0b7332f81222b1)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jun 08, 17, 14:35
Dropped off the conrods and ARP bolt at the machine shop to re-size. Got the impulse wheel removed and everything retorqued.

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FuYxRD7O.jpg&hash=568b21c223aa004361c0a9017927ed20)

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F3Om7WqS.jpg&hash=b856ee4494e0118e226c246700ac08d5)

Got the stripped allen bolt loose on last days off but had looked at the harmonic balancer, like I expected 25yrs old rubber is cracked so be replacing that as well.

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FX75RN2L.jpg&hash=097530a1ffa3cdc7b84047c3366784bc)
Any suggestions? Fluidampr?
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jun 15, 17, 09:27
Still waiting for the Conrod to get back from machine shop so prepped a bunch of parts for paint yesterday and today got the cylinder head prepped and painted. Using my wind driven side draft paint booth:

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FOwAAaqd.jpg&hash=f3bc1cfb0098019149c9a5c55667d05b)

My drying area:

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FYLtlOHh.jpg&hash=f234353e4d2546edfef9fdf80e4162f5)

Cylinder head primed two coats of VHT etching primer, tried VHT Aluminum but wasn't a big fan of how it looked, so doing two coats of VHT Titanium Silver Blue then two coats of VHT clear coat.
Primered:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FV3WbuQF.jpg&hash=1f1b639ded3982d72d2da63ea496b6ea)

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FPTWrLal.jpg&hash=6791536fa48e2caa08eace085aafcf9e)

Yesterday took the alternator apart to see if it was worth rebuilding, ordered new bearing, voltage regulator and slip rings for (http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FPldSMSu.jpg&hash=3790063f3f0f47ca717d7b3a2a8723ed)

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FYH90dex.jpg&hash=62c515b576fdbabe5d49ef7b188ce566)
Also ordered two idler pulley from the UK was the cheapest I could find.
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jun 15, 17, 13:35
Installed new coolant flanges, new "O" rings, clips and cleaned up the temp sensors. Cleaned up the fuel rail, injectors and bracketing.Finished painting the valve cover and put it all back together ready to install on the block.
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FPmtmO9i.jpg&hash=acf9b1e5ec08f68fb7834fc39ba6011d)

Temp sensors corrosion removed:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FiPKx586.jpg&hash=2f8c1bff7c7c25b5e4537cdfa5796f7b)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Autohau5 on Jun 15, 17, 17:42
I painted most of the aluminium on my engine the same VHT titanium silver blue. :) Quite pleased with the colour. :yes:
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jun 15, 17, 17:49
I painted most of the aluminium on my engine the same VHT titanium silver blue. :) Quite pleased with the colour. :yes:

I'm quite pleased with it as well, not as bright as the aluminum paint, with the tint of blue it's just right.
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jun 16, 17, 17:12
So got the conrods back from the machine shop today, started with piston 4 this time around since that one had the issue of the piston hitting the impulse wheel. Well the impulse wheel is out but now the piston is hitting the oil squirter.

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2Fdevq1lm.jpg&hash=2e4d6430e3365f0bb723a49750aa757d)

So removed the crankshaft and measured what I need to clear the oil squirter measurement is 4.63mm

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FcYJUxfQ.jpg&hash=adc718373695d93bebf55b18b8f29770)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jun 17, 17, 15:31
The oil squirter clearance issue in piston #4 is because it sits lower the the other three cylinders.

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FUVrar7k.jpg&hash=8a32a4b027ea8ca1268f3c1035872a1e)

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FRRSHBlu.jpg&hash=70e4fdf4b1168041a89f70fd7a76210f)

Drill 8mm hole through the block for oil return of the Gladder

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FPNBibUw.jpg&hash=f43b02a8a80337a71868e8df2bfe5b77)
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FTCROoHe.jpg&hash=f4b445481a78c5c1ff39cde2d5a20ee3)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jul 06, 17, 11:14
Picked up some the parts today from INA for my G-lader rebuild, seals, bearing, Apex strips, lube.
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F9JehQtj.jpg&hash=7ea173fb1b49b90a4f31d1660b268a6c)

Picked up the G-lader oil return line, banjo fittings, custom hose adapter from 8mm bolt to AN-2

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FPfmasHC.jpg&hash=ad1b474d7ef46a8cafac0fc97a78b311)

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F1ziXVRk.jpg&hash=a06e9badde6d2fea6bdf10a3bfefbaee)

Custom adapter will fit into where I've drilled through the block for the G-lader oil return
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FTCROoHe.jpg&hash=f4b445481a78c5c1ff39cde2d5a20ee3)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jul 07, 17, 14:03
I purchased a cheap bench top sandblaster and some glass bead media. Not 100% where I want it but in time I'll get the parts looking almost new. Two halves of the G-lader:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FOunB7uA.jpg&hash=aa525c591812430db9d35ea04d48b3a0)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jul 08, 17, 19:34
I'm taking the buy back for my 2015 Passat TDI next week, needed some wheels, so got the Corrado a buddy :D Going to drive this until I get the Corrado on the road.
1998 GTI VR6 not perfect but nice solid car, two small rust spot one by the driver's mirror the other on the hood from rock chip, everything else is rust free. Done recently rotors and pads done, wheel bearings, ball joints, poly bushing on all but strut towers those are TT's, serpentine belt/tensioner, O2 sensor, new windshield, window regulator, motor mounts, water pump, timing chain. Everything electrical work with the exception of the cruise control. Needs fluids service, new wheels/tires, rear passenger side ABS sensor. Tranny is good no grinding but long throws so that will need attention, motor 242,000 kms but runs strong, came with ST Coilovers, 25mm sway bar. Interior is mint no tears. It was originally a BC (British Columbia) car so didn't see much snow, it's been well maintained/regular services.

1998 GTI VR6
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FtLhA0tE.jpg&hash=3a48ccf65831b85a82de282f8f029778)

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2F9XyfR4L.jpg&hash=03606a12113e8992754d9ee47cf533f7)

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FrtRoWaz.jpg&hash=d96e4a5b89514c83e2745e77eafcb7be)

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2Fwsir6jm.jpg&hash=b27f32c5855ac7bc0f5d526e95c44ace)

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FctPpnTX.jpg&hash=4ad1e0abab8d36ad1ac30ff1ca6fcdc0)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jul 10, 17, 17:03
Picked up some 3-Piece Mille Miglia MM300 17x8 and 8.5, 5x100 - 5x112 adapters 15mm/20mm for the MK3 Yokohama S-Drives, traded the Bentley's with a Vortex member in my area.

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FXPw7w07.jpg&hash=edd6435044ff381de45c3d1e7837c2e8)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jul 11, 17, 20:56
Picked up the GTI today in Levis, Quebec, was a little anxious about driving a 19yrs old car that I haven't maintained 365 km's, did the pre trip check, tire pressure, oil, powered steering,coolant levels. Fuel it with 91 Octane and went for it, really pleased with the car, no issues on it's first trip. Some general fixes are required to pass the safety, wiper blades, horn doesn't work, CEL was told it was passenger rear ABS sensor, needs wheel alignment and new tires (that's covered). Nail down some rattles, as previously mentioned the long throw in the shifter got to go. Next couple days will be going through it making a parts list. Some body molding need attending to and some require replacement. Swing by body shop to see what can be done about the rust spots. I do like the VR6 exhaust note it is SWEET!

Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jul 13, 17, 16:38
So got the wheels on the MK3 going to need to do some fine tuning to eliminate the rubbing on large bumps. :D But REALLY like the look it give the MK3. Had to use the spacer/wheel adapters 5 x100 - 5 x112.

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FZBwNLtM.jpg&hash=9ae0ec4438b736cb75a84c0255c6a2a9)

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FNmaWo8D.jpg&hash=a9f55d8a9eac825230db976c1f58e566)
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jul 13, 17, 16:40
Had to fix the horn in the GTI for upcoming safety it turn be being steering wheel clock spring contacts, was full of dirt and grime no contact was being made. Cleaned the contacts with contact cleaner tweaked the contact upper a bit. all works:
(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FLuP8ffB.jpg&hash=e07c7d3e52b24268df3e4929f4a3a0c9)

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FOqasVvN.jpg&hash=07d7d8abe82a80280624b99169fbe3fb)

Next is getting ABS sensors to clear the warning light.

Address 03: ABS Brakes        Labels: 3A0-907-379.lbl
   Part No: 3A0 907 379 E
   Component: ABS/EDS ITTAE 20 GI V00
   Coding: 03704
   Shop #: WSC 00000
   VCID: 2C572FADDC73802165-4A84
 
2 Faults Found:
00290 - ABS Wheel Speed Sensor; Rear Left (G46)
            35-00 -  -
00287 - ABS Wheel Speed Sensor; Rear Right (G44)
            35-00 -  -
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jul 13, 17, 16:40
rought the GTI for a pre-safety today, they failed the wheels (which I was for warn when I booked the appointment) the Ontario Ministry of Transportation is cracking down on car with wheel poke and fender clearance (lowered). I've borrow a set of 15" wheels get by this fail, also need to replace outer tie rod end on passenger side, rear license plate light, wiper blades, rear rotor and pads and right front hose support bracket needs to be secured. All parts are ordered and some on there way.

Corrado update:

Got the pistons 4 clearance issue with oil squirter solved, oil pump, oil pan, water pump and cylinder head installed.

(http://dubberz.com/forum/proxy.php?request=http%3A%2F%2Fi.imgur.com%2FzuCg1JN.jpg&hash=96ee0e0887bf644c8dcf36bda5b4b912)

Just notice I've got the water pump pulley on backwards LOL  :hmmm:
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: aba16v on Jul 14, 17, 13:49
Lookin good!

I'm still trying to get that 2.5L on the dyno by the way, rawteks been going flat out and we just got them into the sprinter vans so that's not going to help.
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jul 14, 17, 13:53

Thanks, still interested in getting the tune since I've found out that Unitronics didn't take into account the SAI in their tune, so leaving some performance behind  :undecided:
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: aba16v on Jul 14, 17, 13:55
integrated engineering is the only company that really knows the 2.5L to my knowledge. We've got a great tune on a base motor but not much testing with that intake.
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Northendroid on Jul 14, 17, 14:00
integrated engineering is the only company that really knows the 2.5L to my knowledge. We've got a great tune on a base motor but no testing with that intake. One of our employees just bought an 07 rabbit so eventually we'll coax him into a manifold.

I believe that United Motorsport has it as well. Be cool if your co-worker would upgrade his. We were going to purchase the IE tune with the July weekend discount but there was a glitch in their web page that would give you the discount. Would gladly buy of you guys special if it's tune to our Canadian gas.
Title: Re: 1.8L 8V G60 with AEB Block - lots of pics
Post by: Steel23 on Nov 06, 18, 05:05
Any update on this build?