rallyeman

is there not a thin metal heat shield in two halves rivet around the downpipe? it runs from the manifold to the cat.

silly as it may sound, what about the downpipe heat shield?

I'll second that, loevly job rebuilding and porting my charger. G-Werks.

Thanks again for all the info guys, no just got to source one.

Thanks for clarifying that yellowslc. Hey, seeing as you are in the US can you suggest anywhere I can get one of these flywheels? I've found a few places on the internet but none have seemed keen on international orders for some reason. Thanks.

Maybe that's what I'll have to do, hopefully it'll be ok, I'm sure it will be.

Thinking about it isn't the g60 crank the same as the gti crank? So the fitment would be the same. They also state that a vr6 clutch should be used with the flywheel. Is this because the gti clucth is smaller diameter, and the vr and g60 are the same so i'd be able to use a 1.8 flywheel as you said henny. cheers.

A very simple question (hopefully) for some one to answer. Does anyone know what (if there are any) is the difference between a G60 flywheel and a VR6 flywheel? I ask this because fidanza only list a corrado VR6 flywheel, agolf VR6 flywheel and a golf 1.8 flywheel. Any help is appreciated.

Hello, I've finally got my rallye in the garage in bits now, and so today I went along to my local stealership to order some parts. This included the two tools for setting up the cable change mechanism. They told me that VW UK have none in stock anywhere and they could take 6-8 weeks to get. My question is does anyone know where I can get hold of the tools to do this job? Something which made me laugh was when I tried to order 6 non-stretch crank bolts and washers, their computer said no stock for either, and only 5 bolts and 2 washers available in the UK at this time. I can understand the tools not being stock, but surely Vw must get through quite a few of these bolts? any help much appreciated, thanks in advance.

Ah, that is why red tops are popular, I see, a third the price of gerys. Thanks.

So grey tops flow almost the same a red tops. That is what I wanted to hear, thanks very much.

Could somebody tell me the different flow rates for bosch injectors please, green, grey and red tops. Thanks in advance.

Jobs a good 'un then, I'll get to it.

The reason for this is, I blew my charger a few weeks ago, and have found a complete PG block charger etc at a good price, I was looking for a 1H block/charger etc left over from someones rallye 20vt conversion but no joy. I am going to swap the complete setup, so that I can strip and rebuild my 1H block and create a 16v G60 spec rallye. I like the idea of a 16v g60 rallye, I don't really want to go down the 20v turbo route, I know there are good power gains to be had and they are more tuneable engines but everyone is doing it. I know the 16v option is going to end up being more expensive than a 20vt conversion. This way though I can still use the car whilst I'm building the new engine over the next few months. Then when I'm done and the 1H block is back in my car I can sell the PG block anyway. I think this is the better route to go down rather than using the PG block as a base, because the 1H is the better of the two. What do you think?

So from reading this would I be right to assume that I could swap the 1H block in my rallye for a PG from a corrado without too much trouble? But i will need the gearbox bolts from the corrado to mount my gearbox to the PG block as they are different? am I right so far? Other than that everything else is a straight swap, basically unplug everything take out the old block, in with new one and away.

The numbers above are the numbers taken from the bearings that I removed from the charger on the intermediate shaft. Thast was my question are th bearings I took out the right bearings? Obviously not, from those part numbers listed directly above.

Right, I've got the bearings from the intermediate shaft out now so here it goes they are - large bearing FAG 6003 03 RP, this had very little grease behind the seals and was notchy to turn and had side to side play - culprit?? the small bearing was a FAG 6002 03 RP the smaller bearing was in good condition spun freely, plenty of grease. What do you think?

How about removing the CC on a g60, what do I do with the feed back tio the throttle body?

I have a question, what do I do with the hoses that run to the carbon cannister if I remove it to provide a cold air feed? Especially the hoe that runs back to the thorttle body? Thanks.

I don't like the sound of this. There were some small flecks in the throttle body, and I probably travelled about a mile before stopping as there was nowhere to stop. Would you suggest taking the head off to check? Knowing my luck so far with the G60 I've probably scored the bores and damaged the valve seats. I'll look forward to an expensive rebuild then.

Another query, I spose this is directly aimed at beavis or g-man. My boost pipes (both sides of the intercooler) were peppered with smashed aluminium from my charger explosion. I can clean the pipes easy enough, but what about the intercooler? do I have to replace it or can I get it cleaned somehow. If you suggest replacing it where would I go get a Rallye intercooler made up? Should I worry about the aluminum that my engine must have inhaled, as I also found some small bits in the throttle body? Is it likely that I could have caused some serious damage? Thanks for you time.

Maybe I was wrong to lay blame solely with jabbasport. I took the charger off today and stripped it down. Now what I found was that the charger did'nt have a stock pulley, it was fitted with a 70mm pulley. I would imagine that this would reduce the life of the charger a lot more than a stock one. Inside the charger I found all apex strips intact, all seals looking good (although there was a good coating of oil inside the boost pipes and the charger), and don't know about the conditions of the bearings, but they seemed to be intact and all spun freely enough. But the timing belt had snapped. The only damage I can find seems to be associated with the timing belt snapping, displacer smashed hole in casing and and then smashed itself. The sits of casing and displace seem to have been smashed into aluminium pepper which now covers the inside of the charger. I'll post some more pictures when I get the chance. Should the charger have had a wider than standard timing belt fitted? this looked like the stock 9.5mm belt. Wish I'd have had the charger inspected soon after I got the car. Never mind.

Yeh, I'd be pretty interested too. See how many vandals like me there are about, I'm sure that there are plenty of you out there. Has anyone bought a charger from g-tune (lowG)? any opinions? I'm thinking of an RS2 spec, what do ypou think?

They'll never see any of my hard earned corn after reading this, not for any service or product that provide!

Is that really what they said? That would go some way to explaining why the charger only lasted 25k, I would've thought at least 40k for a standard charger with standard pulley and regular oil changes. What the point of rebuilding it at all if you don't do it properly. Useless.