domwells27

Some info here: http://www.clubgti.com/forum/archive/index.php?t-71847.html Looks like the 1H had oil jets on the bottom end, not sure if this effects comaptibility though

Out of interest, would the hazards still work if the relay was knackered? Or are they controlled seperatly?

Mine runs at around 14v, which I think is normal. 13 does sound a bit low to charge the battery properly. How old is the battery? could be a combination of both old battery and weak alternator

From the knowledge base: "# 148 1000 0 (Atmosphere- ala no boost, charger is bypassed) # 172 1200 2.9 psi (Your charger is dead or big boost leak) # 192 1400 5.8 psi (Your charger is about dead or big boost leak) # 211 1600 8.7 psi (Your charger needs new apex strips or big boost leak) # 228 1800 11.6 psi (Great for stock pulley, Probably needs new apex strips if 68mm pulley) # 242 2000 14.5 psi (Great for 68mm pulley on stock charger) # 255 2200 17.4 psi (Great for 68mm pulley on heavily ported charger, hold on to your ass fast!!) # 255 and up folks need to be careful with fueling, as the programming maps end at about 242 on the ecu. Dynotuning, and air/fuel/egt gauge, and custom chip recommended " Mine is running 1840 on a 68mm pulley at the moment, but i'm due a rebuild.

Well its about time I sort out all the niggling issues with my car, so i may as well be able to see the time in the dark. What size/type bulbs are used in the instrument cluster. I'm after the one which backlights the MFA and the ones which shine down on the dials themselves to illuminate them. Any ideas? If i could avoid going to VW that would help as it's a bit of a trek for me just for some poxy bulbs! Cheers Dom

I'll try and clean up the connectors but they didnt look too bad. If not i'll put up a wanted ad Thanks for the help

So recently my indicators have been playing up. First of all: the bulbs are fine and the hazards work as normal. Sometimes when putting on the indicators they would gradually get faster until the relay started to buzz. It seems that jiggling the stalk a little bit sometimes made them work ok, which made me think maybe it was a bad connection in the stalk.. I took the stalks out, checked over the connections and wiring and everything seemed ok. Plugged it all back in again and they were fine for a few days but now they are compeltely dead. Sounds like the stalk is dead, is it common they go completely? They seem pretty sturdy. Also, would the hazards still work if the relay was borked? Cheers Dom

Wow great find. Interesting to see the charger being cast and machined

Wow! Spent this morning reading this whole thread. Much respect for the sheer amount of determination, time, effort and workmanship gone into this. Reminds me of this thread I saw recently: http://www.s2forum.com/forum/showthread.php?t=19402 When i have more time, money, space etc I have to do something along these lines!

If you've got one near, halfords or Wickes will do them. Result! Have got all those shops but not within walking distance, however I managed to find one lying around the house, who needs a saddle on a bike anyway!!??

Just spent over an hour trying to get the silencer box off. Finally got it off only to find out the bolt is too short for my new charger outlet!!! Now car-less until I can get a longer m8 bolt :(

Well after a few quiet days at work I've finally got round to making my DIY charger outlet. Here's some piccies to show the progress. Just roughing out the profile Inside profile machined out. Air channels milled out and blended (really badly!) Finally, o-ring groove machined and fitted with o-ring If your wondering about the weld I was convinced the hole was should be 14mm. Only later found out it was 8mm :epicfail: Had to make a bush and press/weld it in. D'oh! Just ordered the plumbing for it so should hopefully be able to fit it next week and test it out. Also got some Koni suspension waiting to be stripped and re-painted. My car desperately needs lowering so cant wait to fit these!!

Changing the bits is relatively straight forward, you could do it yourself if you have the tools. The only tricky bit IME is getting the belt tensioner back on. And make sure the woodruff key is lined up when you fit the new pulley.

sounds like the ignition switch. try wiggling the key in the barrel next time to see if that helps

Ok thanks for that. Wont have time to do the cambelt now anyway as the feckin water pump pulley bolts are rounded too :censored: I'll see what contraption i can cook up for the damper, was looking at large g-clamps to compress it. If not i'll have to fab something up at work

Ok so had a go today. What a nightmare!! Managed to get the rounded bolts out, thanks for the suggestions. BUT......... couldn't get the lower cam belt cover off!!! Does the water pump pulley have to come off? Now there's no tension in the v belt obviously and now I can't get the tensioner damper thing back on. Sure theres a bodgy way to do this but tried with 2 of us and brute strength and it wasn't going on. And to top of a really shit day the power steering belt that europarts gave me is 7mm too short :censored:

Yeah i've heard good things about these, but looks like they only work on traditional hex head bolts, not allen key bolts??

Thanks for the advice. I've got a 7mm allen key socket i was going to try and jam in there, if not i'll try a larger torx key. Failing all that I was thinking of using a screw extractor, but heard mixed things about them

Thanks for that. Had a quick look earlier and looks like one or two of the bolts are rounded :roll: Any advice to get them out? Not sure i can get any mole grips in there and no access to a welder.

Ok so i'm planning on doing this at the weekend. Whats the easiest way of lokcing the crankshaft up? Looks like the v belt bulley will be difficult to get off if its moving.

Which engine?

Amen. I'm in the exact same situation as you, just wished i lived closer to G-werks so I can drive in and have the charger rebuilt. Guess i'll be cycling to work for a while some time soon :(

Good spot, thanks for that :)

Picked up the 4 set of spanners today. Even the sales assistant couldnt believe the price. Don't forget they come with a lifetime guaruntee :)

Good spot at a bargain price. Shame I can't find a need for these sizes, although track rod ends need doing soon, same size??