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1.8L 8V G60 with AEB Block - lots of pics

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northendroid Avatar
northendroid Jack Landry
Cornwall, Ontario, Canada   CAN
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 an 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. AEB blocks are used in Passats and Audi B5 A4 the early AEB is a 056 with an external water while the later model is an 06A which has an internal water pump.These are 056 with external water pump like the PG block.


Will be using stock 81mm pistons with new rings, stock conrods bolt up to the AEB crank conrod journals:


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:


Modified to fit in the area:


Drill thru block and tap this existing bolt hole to accept the G-Ladder oil return


Install a frost plug:


Install crank position sensor (not used - only fills the hole):




An AEG head gasket is used with the stock 8V head, the three rear oil journals will be blocked when using this gasket:


Purchased BBM Stage 4 chipped ECU, 3.5 bar FPR, 268/260 cam, 65mm pulley


The intermittent shaft gear is the same pitch as the PG distributor:


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:




2015 Passat TDI Highline (SEL) "http://forums.vwvortex.com/showthread.php?7177186-Bagging-a-2015-Passat-Build";, 2005 Bentley Continental (98474) 19x9 ET41 235/35/19 - Air Lift Performance Series - 3 H/P Air Management, Whiteline End Links, OEM Sport Pedals, 20% Window Tint, Black Wrapped Roof, Headligths from Kraftig Tuning
1991 Corrado G60
"www.instagram.com/ridelower"

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northendroid Avatar
northendroid Jack Landry
Cornwall, Ontario, Canada   CAN
Took the engine apart today to see why it was knocking

http://vid1239.photobucket.com/albums/ff512/xbox360guru/1991%20Corrado/IMG_0733.mp4

Bearing is MIA:


Crankshaft is toast, it also has a tight spot when spun:


Bearing from cylinder 2 & 1





2015 Passat TDI Highline (SEL) "http://forums.vwvortex.com/showthread.php?7177186-Bagging-a-2015-Passat-Build";, 2005 Bentley Continental (98474) 19x9 ET41 235/35/19 - Air Lift Performance Series - 3 H/P Air Management, Whiteline End Links, OEM Sport Pedals, 20% Window Tint, Black Wrapped Roof, Headligths from Kraftig Tuning
1991 Corrado G60
"www.instagram.com/ridelower"

northendroid Avatar
northendroid Jack Landry
Cornwall, Ontario, Canada   CAN
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 smiling smiley





2015 Passat TDI Highline (SEL) "http://forums.vwvortex.com/showthread.php?7177186-Bagging-a-2015-Passat-Build";, 2005 Bentley Continental (98474) 19x9 ET41 235/35/19 - Air Lift Performance Series - 3 H/P Air Management, Whiteline End Links, OEM Sport Pedals, 20% Window Tint, Black Wrapped Roof, Headligths from Kraftig Tuning
1991 Corrado G60
"www.instagram.com/ridelower"



Edited 1 time(s). Last edit at 2017-01-09 04:21 AM by northendroid.

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