Alternative Solution to the By-Pass Kits for G60's ($45)

This is a plug. As such, please do not post it in whole or in part to any discu ssion group or forum where it would be considered inappropriate due to commercia l content. It is not my intention to slam Neuspeed, New Dimensions, AutoThority , or any other of the fine aftermarket suppliers developing VW performance parts . The bottom line is simple: the concept behind the Neuspeed Gen2 kit is good. It works, but you do not have to spend $200 to get the same effect.

A brief explanation of Neuspeed's Gen2 kit:

While it is called the "HP2 Fuel Enrichment Kit" (also "Gen2"), there is more to the story. Fuel enrichment is not the key ingredient. The Gen2 modifications increase boost levels by eliminating pressure losses caused by leakage through t he Idle Stabilizer Valve. When the motor is idling, the ISV regulates air flow from the bypass tube to the intake manifold to control idle speed. Under boost conditions, the ISV can reduce boost levels by bleeding boost pressure from the manifold into the bypass tube. One unfortunate side effect of the stock set-up is that the bled air being returned to the inlet of the G-60 is hot (from having already gone through the G-lader at least once), and increases the charge tempe rature (which reduces power output and increases chances of detonation).

The Gen2 kit (and others) reroutes the ISV, disconnecting it from the bypass tub e. The immediate gains are noticeable. A G-60 motor with the small blower pull ey will make only 14.5psi max. with the stock ISV routing. A leaking ISV may b leed that down to as low as 10psi. The same pulley with the ISV rerouted makes 16.5psi max. The benefits are similar even with the stock pulley.

The Gen2 kit also comes with a "fuel enrichment" system. It is the same as the enrichment system that has always come with their HP kits. It ties into the fac tory's system. The stock G-60 motor has fuel enrichment that is activated at fu ll throttle only. Neuspeed's "hobbs" switch parallels the full throttle switch , activating the enrichment by boost rather than throttle position. There is so me discussion as to whether or not this serves a real purpose. A boost gauge sh ows that it is near impossible to get more than a few psi of boost without havin g the throttle wide open (even with the ISV rerouted).

Is there a down side to the Gen2 kit? Not if the engine is in decent shape to b egin with. Neuspeed claims it adds 17hp. Anything that adds power may have a s light impact on longevity, but the 1.8 block and head are very sturdy from the s tart. The kit does not seem to increase oil or water temperatures at all. It i s a great may to get more from the G-60 without spinning it any faster. If your ISV was developing problems, the ISV reroute should improve your idle. Neuspee d has gotten an exemption number to make their kit legal in all 50 states. It s hould have no effect on emissions test result, and is virtually unnoticeable dur ing a visual inspection of the engine compartment.

If you have a Neuspeed HP1 kit and want to upgrade to the features of HP2 (Gen2) , all you need is the ISV reroute parts. The ISV reroute can be added to any G- 60 motor, regardless of previous modification. If you are running an AutoThorit y Stage 1, 2, or 3 kit you can add the ISV reroute. The AT kits that included t he high pressure Porsche 944 fuel regulator already provide fuel enrichment. If you do not have any aftermarket enrichment you have two choices. One school of thought is to do without enrichment. Again, it is rare to have a high boost, p art throttle situation which is when the "hobbs" style of enrichment is activate d. Without the "hobbs" switch, this situation could result in the mixture getti ng lean and causing the knock sensor to retard the timing. The drop in power wo uld probably cause you to open the throttle all the way, engaging the factory en richment switch. The other option is simple. Buy a "hobbs" switch (from NAPA) and wire it to the factory throttle switch. Put small plastic "T" in a manifold pressure line to sense boost level and suddenly you have boost sensing fuel enr ichment.

Hopefully you now have an understanding of what this plumbing trick is all about . Rerouting the ISV is a neat way to get more power at little cost. The fuel e nrichment system is already in place on many cars. If you do not have it alread y, it may not be required. You may want to wait and try the ISV reroute before determining if you want to add the "hobbs" switch.

The hard sell:

For $45, I will sell you a complete kit of everything you need to install the IS V reroute. It works on all G-60 Corrados* and other G-60 equipped motors which have the ISV. It comes with very easy instructions. If you know how to use a s crewdriver, installation takes about 30 minutes. There are not very many pieces . The most important component is the junction fitting in the boost tube. A nu mber of people reported problems with the fitting supplied by Neuspeed. Some we re sloppily made and required a lot of clean up and de-burring before installati on. I take great care in fabricating the fitting that comes in my kit. It is r eady to install right out of the box. My kit also includes complete instruction s for installing a "hobbs" switch enrichment system on your car if you want to a dd it. I include a list of parts that you can get at your local NAPA store (abo ut $30 in all); installation is easy and takes about 20 minutes.

I have not sought an exemption number, so you get this disclaimer: Parts may be considered not legal for use on pollution controlled vehicles -- check local la ws. In WA, we have to emission test every other year. Visuals are done randoml y on cars passing the sniffer test. ISV mods will go undetected. If you are un sure, you could remove it for the test. It takes about 5 minutes to remove/repl ace after the initial installation.

*A small percentage of 1992 model G-60 Corrados require an additional hose. It is not needed for 90-91 or most 92 cars. I don't include this part (neither doe s Neuspeed). If you have one of the few 92's that need it, the additional hose is about $12 at your local auto parts chain.

How to order my kit:

Send $45.00 + $4 shipping to:

Michael Daily
2856 SW Adams, Suite B
Seattle, WA 98126

Please remember to include your shipping address and a daytime phone number. I fabricate the fittings once a week, so you might want to e-mail me and tell me you have set in an order. That way I can reserve one from t hat week's batch. Otherwise there can be up to a six day delay in getting it ou t to you. You do not have to e-mail me (MDaily632@aol.com), but if you do I can usually ship a kit to you the day after I receive your order.

For international orders:

Outside of USA, send (US)$50 and I will ship via UPS international service. UPS will collect freight, duty, and taxes at time of delivery. The extra $5 is for filling out the stack of necessary paperwork.


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