The history......
Bought my G40 just over 4 years ago, completely standard in capri green. The initial journey to pick it up from just outside London was a story in itself.
Anyway, had no idea if the car was going be a heap or a winner. Turned out to be a winner
- drove the car from London to Holyhead - then Dublin to nearly the Top of Northern Ireland using nearly 2 tanks of fuel, driving nearly 600miles, and many 120mph bursts [to make the ferry, which we did....just] all the while, it didn't miss a beat. If that wasn’t a test for the engine, I don’t know what is…
Unfortunately I have no pictures anymore of the polo in its standard form
so this build thread is off to a great start haha...
Shortly after getting the car home, I signed up to this forum and it was the best decision I made in Polo terms. The help and advice has been brilliant because to be honest, I didn’t know a terrible amount about the G40. Some of my earlier posts are embarrassing to say the least haha, but you have to start somewhere
After staring at the forum for countless months, I found out about ported chargers and 65mm pulleys – so bought a fully rebuilt, ported [full blend] charger and got a 65mm pulley/chip – completely transformed the car. The only problem was the need for sticky belt dressing which covered the engine bay…nasty.
Also did the boost return mod, added a 51mm throttle body, a GT inlet manifold and fitted new coil-overs with new steel wheels [195/45/14] as well as a few other minor things.
Ran that setup for quite a while and thought about toothed pulleys, but decided to go the turbo route instead. The cap on power the charger can provide was a put off as well as the need for 20k rebuilds on the 65mm pulley. Turbo route had more advantages in my opinion.
So from memory I bought all the following parts for the turbo setup:
- K03 turbo
- Manifold
- Downpipe
- Oil feed/drain
- Water cooling pipes for turbo
- Sump with turbo oil drain
- 268 Camshaft
- 6psi boost switch
- Cg Motorsport Kevlar clutch
- Universal front mounted intercooler
- 16 row Mocal oil cooler with thermostatic sandwich plate
- Full 3” stainless exhaust system
- Oil pressure, temperature and boost gauges
- Remap
The end result was [finally a few pictures]:
After getting it mapped with a K03 – it made 175bhp using 17-18 psi of boost – he then took it down to 170bhp with 6 less ftlb. of torque and said its at its limit in fuelling and this made it slllllightly safer…. He is an absolute genius and pulled a ridiculous torque figure out of the map which I’m not going to post as I reckon it will get slammed. And since I didn’t take a video or picture of the mapping session or get a printout of the figures, I cannot backup my claim other than say it’s my word.