G60 (Supercharger Unit) [Buy/ Remove/ Service/ & Refit] Work

[pagurus 0]

Welcome to this sub-thread on refurbishing my (Red) 1992 Corrado G60.

 

I blew the supercharger when the charger timing belt broke.

There are nice new holes in the charger casing.

See the primary thread for this work here ...

The Never Ending G60 Corrado Refurbishment Project

http://the-corrado.net/.archive/forum/viewtopic.php?f=1&t=89928

 

Use this thread for general info on refurbing your G60 supercharger unit, and or sourcing another car for spares.

This one will be removed from the vehicle, sent down to Gwerks for a service then fitted to my primary (red) G60 Corrado.

 

So I have bought a (blue) G60 Corrado for over £1K for spares.

Why spend so much just to replace the supercharger which will need a £400 service anyway!

My (Red) G60 needs so many parts to refurbish it, that buying another better car seemed a sensible option.

 

This sub-thread is about removing the replacement car supercharger, and things I have found along the way.

 

I had originally hoped to simply take the second car's supercharger off, bolt it onto my red car and drive it down to Gwerks for a full 12 month warrantied charger service. Ahermmm!!! :brickwall: Things didn't quite work out that way...

 

Please bear in mind any info I offer on here is layman's advice only. I am a real beginner, but learning quickly as I go along. If in doubt, get a second opinion.

 

I made a b-line for one in completely stock condition. No bad-boy race mods, no fangle chargers under the hood, all bits in working order and a tidy front end with good lights and bumper cos my car's front end has had several prangs.

 

The replacement car was advertised on ebay for spares, and after some eye watering bidding, I won it for £1,170.00 (Ouch !!)

See the compressed ebay pics below ... climatronic wiring-Golf from May 01.pdf2010 03 01 - Ebay Purchase-Jan31st92Corrado-Resized.JPG[/attachment:1hfcly35]

Caveat Emptor (Let The Buyer Beware), Half decent unmolested G60's are starting to get as rare as rockin horse s**t!

Expect to pay through the nose for one!

Next problem - it's in Kent, about 250 miles away.

The seller was really helpful and driving it back to Manchester on my third party (any vehicle) insurance did the trick.

If your doing it strictly by the book, you should really arrange separate specific insurance through your insurer.

Adrian Flux do this and offer 1 day or 1 week insurance for about £100.

We didn't complete the V5C paperwork and title sale transfer until I had it back to Manchester (wink wink). :wink:

I checked the car was taxed, and fully insured by the seller through their motor trader policy before setting off.

Sorry if this is stating the obvious, but - you MUST MUST arrange this BEFORE travelling down to collect your motor.

 

I bought the car solely on the strength of the pics and a conversation with the seller. He seemed a genuine bloke, had been trading on ebay for 6 years, and had nearly %100 positive feedback. If any major problems presented themselves when I collected the car, It was probably too bad! Always view before buying if possible. As luck would have it, I didn't do too bad with this one. It started sweetly, and I had been assured that oil and water levels were fine. I had got assurance from the seller the radiator fan kicked in when the engine got hot, but it's probably best to check this before you set off.

 

The car ran fine and the juice cost about £40. No smoking or strange noises from the engine, no strange noises from the supercharger, no crunching from the gearbox, no overheating, spoiler, sunroof, windows, rear wiper jet, front wipers all working. Happy days :lol:

 

After 237 trouble free motorway Miles, it did leave me stranded on a car park about 3 miles from home. A bump start from some helpful cabbies had me on my way again. After stripping out the charger and rad, I discovered some very dodgy wiring to the starter motor. Mystery solved!

 

The next day, I sprayed wd40 on all the charger fixing bolts I could see. The idea was to unsieze any bolts that might be a bit tight. It takes a few days to penetrate. (Not sure if there is specialist penetrant oil available)

 

A few days later when I had chance, I stripped out the supercharger.

At this stage I have a crappy toolkit, but as this was my second charger removal, I had a few tricks ready to go.

 

Check this link for general info on the G60 supercharger from a very acomplished enthusiast

http://corradog60project.blogspot.com/2008/10/glader-supercharger.html

 

Check this site for info on the charger rebuild process:

http://www.matey-matey.com/g60-rebuild-article.shtml

 

Check this site out for info on removing your charger unit and getting nice new spangly fixing bolts for it!

http://www.kompressorkanada.ca/node/46

 

2.8l 24v Climatronic system.pdf2010 04 24 - G60 Blue Parts Charger Before Removal - IMG_2872.JPG[/attachment:1hfcly35]Note the oil leakage around the charger inlet and outlet port casing connectors. I think this is a sure sign the apex seals are heavily worn, but I guess the G-Werks guys will confirm this when they recieve it. The charger made no strange noises during my journey home, but it didn't provide much boost either, so I'll keep my fingers crossed.

 

2010 05 02 - Came across a manual and an excellent exploded pic of the supercharger.

Should come in handy for ordering bits and pieces for the reinstall when it returns from G-Werks.

It has the Torque settings too. Nyone know how accurate these are in practice?

G60-Exploded-Parts-View.jpg[/attachment:1hfcly35]

Keep coming back for further updates to this thread.

Cheers !

[pagurus 0]

On both the replacement and original cars, looks like there should be a gasket behind the lower part of the Charger bracket where it mates to the engine block. It's an unused port anyway, on the G60 at least. Anyone know about a gasket for this to ensure a good seal, or any good solution? Looks like sealant has been used before on both cars, and it hasn't kept a good seal on either of them.

Cheers for any help with this.

Charger-Bracket-Gasket-Needed-IMG_2899.JPG[/attachment:gcntmfdj]

[drewiee99 0]

if i remember right its just an o-ring on the back of the charger support bracket and pop a bit of silicon round the edge and bolt back on.

[Henny 0]

yup, I can confirm that drewiee99 is correct... it's a rubber O ring.... Think mine cost about 90p from VAG when I rebuilt my G60... 8)

[pagurus 0]

Cheers - drewiee99, I'm tryin to keep this refurb pure. No silicon unless essential. I'll look up the o'ring option buddie.

[pagurus 0]

Cheers - Henny. There's an 'o' ring on both the engine block and the bracket itself. It could just be staining from a previous o'ring. Rob at G-Werks has promised to pop one in the box when he posts my serviced charger back.

[pagurus 0]

Here's a list of the bits I'm buying for now in preparation for the charger re-fit when it comes back from G-Werks.

The budget's getting squeezed, so I'm gonna pick the best bolt fixings between the two cars.

 

~Can anyone recommend a decent Anti-Sieze compound for the bolts?

 

~Can anyone say where to get part number 29 from?

It's a large round profile gasket that sits in the middle of the silencer halves. VW guys say you can't buy it anymore.

 

~Can anyone recommend a decent silicone sealant?

 

~Can anyone recommend a brand of really decent screw spiral 'o' clips for the larger hose fittings? Mine are a bit tired and rusted.

2.8l 24v Climatronic system.pdf0-Supercharger-Refurb-Replaceables.jpg[/attachment:1jfh8o8p]

1-Charger-refurb-Replacement-Fitting-Parts-List.JPG[/attachment:1jfh8o8p]