Dave.Warlord

Did you ever do anything with your rear lenses?

Think I may have solved it. Flicking through the bentley I noticed you can adjust the offset of the water pump pulley although not as easy as they make it sound :) . Seems much better now. Straight edge shows a couple of mm diference from the bottom pully to the charger which I rekon I can live with with the pulley being further apart. Cheers for all your help .. again :D

Unbelievable :clap: Is your mate a magician :)

Same here and its aint fun. When it happend to me I thought it was judgement day. At least your ok

Cheers lads Car was in storage for three years mate while I did houses and kids and stuff. Only came back out at the end of Feb this year after a rebuild. Back for a month or so and just finished running it in then :epicfail: Hopefully gonna put some miles on it through the summer and do some shows and meets. Then shes off the road again for the winter to do what I've done to the bay to the underneath and the rear. Gonna have the RS's re-done. Either re-polished or chromed. Aint decided yet. The plan was to get her running sweetly first with 200 ponies under the bonnet. Hopefully should have that now... Fingers crossed

Hopefully these will be the final pics before the grand starting ceremony. As soon as I get the serp pulley problem sorted the old girls ready for a run :D Now on day 54 of a job that was gonna take a weekend :lol:

I've taken it apart again and nothing looks worn. Its a new crank pulley and new bolt. Nice and tight with a 6mm roll pin added for good measure to prevent the dreaded crank pulley problem. Heres a pic showing the offset of the serp pulley. Its 20mm if you can't read it. If I can get one with a 15mm offset it should line up perfectly.Maybe off another vw

Yeah exactly. Glad its not just me thats confused. The other thing I cant understand is if the pulleys have always been out of line why has it only just started making the chirping sound after 8 years.

Part number is 037 105 255. On the exploded drawing above though this is the same part no as the top setup. As mentioned before mine is the lower one with the vib dampener on the outside of the serp pulley. Part number for that is 027 105 243 but is listed for KR,9A. Surely if a prevoius owner had changed it all for some reason the pulleys would be way out. :confused4: :confused4:

I think I have no choice other than to put the belts back on and see how it goes. The only other thing i can think of doing is have a few mm machined off the crank pulley but then the PAS pulley wont line up and i'll have to space it out. Getting pretty sick of it all now. Think I'm gonna chop it in for an air balloon

Yeah all the other pulleys line up perfectly. Locating pimple on the serp pulley is correct. Just finishing putting it all back together after havint the block out to sort a cracked piston. Only noticed it when i was putting the charger back on today. Usually you can't see directly from the front but with the front end not being on you can eye up the pulleys. Cant understand it mate.

Mine (1991 G60) has crank pulley, then serp belt pulley, then vib dampener, then PAS pulley. So it only goes together one way Mines the lower setup in the pic below which has totally confused me now cos the parts manual shows this as the Kr,9A setup not the PG. Ive had the car since 2002 and its been like this since I bought it.

Hey Yan, I know this is an old topic but I think I may have found the problem. I noticed after putting the charger pulley back on that it lines up perfectly with the water pump pully but the pulley on the crank sits about 5mm further out. Confirmed this with a straight edge. The serp bely pulley/pas pulley are original but the crank pulley was changed at a garage before it went off the road a few years ago. Do you rekon its possible they have put the wrong crank pulley on and mine is 5mm too thick? Cheers

Thanks mate..... lets hope she starts :pale: Or it will be a real pretty ornament :wink:

Well if anyones still reading this topic I'm getting close now. One final mock up before all the IC pipes and fittings are welded up, fluids and and a few bits and bobs and she should be ready for a run. Getting nervious about the first turn of the key now though. Hopefully be back on the road for the CCGB meet at Cosford later in the month.

Ah I see. Cheers

Does the Golf G60 support rod have a bend in it to miss the pipework? I'm just in the process in fitting a FMIC and was thinking of making a custon support as its a little tight or just not putting it on at all.

I could do with a little advise if someone will indulge me. Would it be best to remove the boost recirc pipe and go from the rocker oil breather to a catch can. Then from the catch can to blanking plate on the chargers boost return inlet? Then reroute the isv back into the throttle intake. Or As above but let the isv breath to air. Or Leave it stock Or Any other suggestions I have not considered. I must have searched for 3 hours now and can't quite find a straight answer :bad-words: . Cheers (Stage 4 charger, 68mm pulley, front mounted IC)

Started having a look at making the charger outlet today. Parts for the IC are being cut out and hopefully will get them by the end of the week. Got a rough idea on how the boost hoses will go now and just need to decide exactly on the angles for the rest of ally and silicone I need to order when the IC is finished. Got the water hoses back on and a good amount of the loom sorted.

Lots more progress. Trimmed the intercooler down a bit and removed the plastic ends. Mocked up with cardboard how I want it and shall do the cad drawings over the weekend to send to the lazer cutters early next week. Changed the cracked piston today (woo hoo :clap: ) as that was what all this started out as and put the head back on. Also the charger bracket and PAS pump.

Powdercoated everything but the block and gearbox

I had to have a few days off working on the Rado. Working full time and spending every night in the garage untill midnight was starting to ruin me. To the point where I was just milling around aimlessly scratchin my head. All refreshed now got the block and gearbox in and been sorting through the loom. From the way its wired up from the factory, I think ze Germans had big shoes and red noses on cos its a total joke with about 4 miles of unnecessary cable. Also been just mocking up the front intercooler and deciding where and how I'm gonna run the boost hoses. Maybe thinking of putting an oil cooler where the orignal intercooler was too.

Got a new one to fit m8. just didn't wanna scratch it when I was jockying the engine in with a jack :wink:

Starting to feel like I'm getting some where now :) Hopefully gonna get the block and tranny back in tomorrow.

Well got a subframe now (second attempt) and its in good nick. I was blasting the upper front crossmember today ready for powercoat and I thought the rust on it was just surface. How wrong I was. Rotten as a pair Looks like another trip to VolksMagic. Now the third in a week. Will it never end. I must have spent nearly a grand now in the last 3 weeks. Its a good job I love it