Vw Polo mk1 G60 - 196 Bhp / 228 Nm

[PR23M3K]

Hello,

I would like to show you my baby ..... it is Vw Polo G40 '94. I bought it 3 years ago. It was fully stock.

Modifications done:
- polished G60 RS charger,
- german toothed pulleys (28 tooth charger pulley at the moment), additionally I have 22 and 24 teeth charger pulleys,
- custom charger bracket,
- custom chip,
- G60 injectors,
- Bosch W4DP0 spark plugs,
- ported head,
- aluminum air intake 77mm => 70 mm by the charger,
- air filter K&N,
- polished rocker,
- polished Polo GT inlet manifold,
- polished de-wedged throttle 48mm
- IC from Audi A3
- 4-2-1 exhaust manifold
- Jetex exhaust system – 2,5"

Suspension: Koni + H&R kit 80/60, front and rear brace bar

Wheels: PLS Hockenheim,
- front: 8,25" ET 6 – outside rim 3"
- rear: 9,25" ET 6 – outside rim 4"
- tires Continental 175/50/13

Body: removed rear wiper, smaller mirrors

Interior:
- 3 VDO gauges: oil temp and pressure, voltage
- AG SM Peak boost gauge
- modified clocks
- steering wheel: Raid HP 28 cm
- shift-light

Plans: new CatCams camshaft 267/281, 250kPa or 300kPa map-sensor, 24 or 22 teeth charger pulley and custom remap. After that I will search for a new body, I want the Polo mk1.

I bought the car in 2008, below photos:













Chart from the rollers. Stock car: 0,6 bar of boost:
Result: 106.6 HP, 153 NM


Next I have done following modifications:
- charger pulley 65 mm + SLS chip,
- FMIC from BMW
- de-cat
- Polo GT inlet manifold
- de-wedged throttle body (48 mm)
- rear and front brace bar

Unfortunately I did not measure power after these modifications. I sold the G40 charger in winter 2009 and it started .... :-)

Polishing:




new charger ...


Refreshed wheels:


Mounting the G60 charger:


and it's ready for 2010 season:














At the end of 2010 season I have added: toothed pulleys, 4-2-1 exhaust manifold and Jetex 2,5" exhaust system.

In 2011 I worked under the air inlet, new IC. I've wanted as much as possible of aluminum.


Pipe from the charger to IC


Almost finished, you can see the new headlights, air inlet on the bonnet to the IC




Clocks at night, the red LED light below the VDO oil temp gauge is shift-light, useful thing ...


It is not a full story, but the most important informations.
75 mm (28 teeth) charger pulley produces 1,35-1,4 bar of boost.
Next week I will check this setup on rollers.

[djtez]

Eager to see results of the rollers!
This is how I'd like my car setup!!

[PR23M3K]

Chart from the rollers, setup as above, boost: 1,35 bar
180,7 Bhp, 226,5 Nm



Now I can modify the engine more and check it once more.

Parts to be mounted this weekend:

• New camshaft CatCams 267/281
• Vernier pulley
• Charger pulley 24 teeth
• Throttle body 52,61 mm
• and custom remap with 250kPa map-sensor
  

[PR23M3K]

Result with the CatCams camshaft, 250kPa map-sensor, 28 teeth charger pulley and custom remap.
196,6 Bhp / 228 Nm


I need to change fuel injectors before I go with 24 teeth charger pulley.
Over 1,4 bar of boost it is to lean at the moment. I am looking for ~310 cc/min injectors.


I have also bought a new body, so there will be a lot of work through the winter

[cheddarcheese]

Nice Results and that will be one quick mk1 

[Jezza-7]

Do you use the standard g40 lader bracket to mount the g60 lader?

[PR23M3K]

At the beginning it was a modified standard G40 bracket, now I use a custom made bracket

G40 bracket:


Custom bracket

[djtez]

Wow cracking results!
Must be monstrously quick.

Any bottom end modifications ? Ie up rated Conrod or pistons?

I want to g60 my polo but value to opinion on here which is basically dont do it

[PR23M3K]

The bottom end is fully stock.

Engine is out and I am working on the mk1

[djtez]

Could you give me a little guidance on how a could sorta follow your set up..
Whhere can I find charger bracket? Do I need to buy another toothed pulley for charger?
What size of pulley can a run and still drive quite erratic..

Thank you in advance if you manage answer any questions

[PR23M3K]

To fit G60 you need to:
- modify stock charger bracket or buy special for example on ebay.de (30-50 euro), for special bracket  you may need longer oil return hose
- modify outlet dome as you can see above
- move a little bit a water cooler

Charger pulley is the same as for G40. 28 teeth (~75 mm) generates 1,3-1,4 bar of boost. It drives ok unless you have 175/50/13 or 195/45/13 tires but you can always put a bigger pulley.

What set-up are you currently running ?

[ereeiz]

Not seen a G60'd polo for a while. I was going to ask how you managed to drive it with the steel wheels on there, then noticed that was the original look for it, haha. Nice one!

[djtez]

Set up is quickly
Big valve head ported and polished on outlet
Piper high lift cam
R1 spec charger
Toothed belts 65mm
G60 injectors
Gt inlet.
Sns stage 5 generic chip
Full ppp exhaust including manifold.... Was hopin id not be far below 165flywheel,
Tyres size and compound are 195/45/14's on uniroyal rainsport 2

[PR23M3K]

djtez, yours setup will easily gain 200 bhp using G60 charger, bigger injectors and after remap of course.

Macadamia bronze on Mk1  :

[djtez]

im Thinking of a wossner 77mm piston set up  ( 1341cc )

now im still having some confusion on the G60 rs stages .
ive seen rs rs2 rs3 and also rs gt , which charger are you using ?