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Late 80's porn? Its a 92 run out. Ha ha. Love it, the advantage of a 4 door is that the shell is allegedly more rigid, and they cost more when new. Love it, i think people ruin the g60 by pulley changes and deleting the return pipe from the tb. The return pipe is important as the crankcase oil mist helps lube the charger.. as you have said they are stressed enough without adding pressure.
Thankfully it's still running the return pipe and a proper air box as opposed to a cone, I've decided I'm going to be either returning it to stock power or just a little more, 180 BHP max. It's had some head work as well so I shouldn't need to screw the nuts of the charger.
Little update and I'm after opinions on this from folks who have built up G60 engines.
To try and cut a long story short I dropped the oil out of this Golf to find a horrifying amount of debris came out with it. Mostly bit's of old head gasket by the looks of things as well as gasket sealant and other crap. As it's obviously had a very recent head gasket I figured the muppet who fitted it made no effort to stop crap falling down the gallery's and didn't removed the sump to clean it out.
I had to have a look inside for signs of oil starvation so I started stripping the cam cover off whilst a 30 year's in the profession mechanic friend went down the pit with clear instructions from me to drop the sump and oil pump then examine the main's one by one as in the event of oil starvation or contamination they always cop it first.
I went down the pit to take a look as he says apart from a lot of debris in oil pump pick up everything looked fine, I then discover he's taken the big end caps off not the mains.
I knew before I sent him down there that the big end studs are single use stretch items in G60's unlike all the other VAG four pots it shares a block with and I would only have removed them if I'd found damage on the mains.
I've since inspected the mains and their fine as are the big ends and top end so I've gotten away will the oil contamination as far as I can see. The oil pump pick up gauze, oil cooler and filter seem to have done their jobs and stopped anything too nasty getting at the bearings. I have a brand new cooler ready to go on as they should always be changed in event of engine failure or heavy contamination.
But now I have to replace the big end studs which as far as I can see the head has to come off in order to get the rods out to work on them. To add insult in to injury their a tenner each from TPS and are NLA, though they have managed to find me a set.
My questions are A, is there a way of replacing the studs insitu? ie fabricate a pushing tool to safely extract them from the rods.
And B is it really all that necessary to replace them? I'm guessing it is.
I could throttle the idiot! Reminds me why I NEVER normally let anyone else touch my cars, I did have a lot of faith in this guy but that's gone as he obviously can't follow simple instructions.
As the parts are on back order the car is now stuck over my pit meaning I can't work on anything else I also have to rebuild an engine for no good reason which I REALLY don't have the time for ATM.
I'm beyond furious.
On the plus side the car itself is even tidier than I first thought, I've sorted out the inevitable poor alarm installation/ICE vandalism and the loom look's stock again, that job alone took a day. Also fitted new window regulators to the front doors and fixed the central locking.
Ouch! In a similar type situation our local power company c*^ked up all my hard work for a new main by being muppets and doing something totally different to what was planned and logical so i know your anger only too well! Although I think I would be even more furious if it was on my car!!!!!!
Think that chap owes you one hell of a favour or a few quid.
Kay I had this when I 're ringed a mk4 git. Trust me you will be fine using the old studs.
Thanks Steven, take it the deal is the same with the four cylinder 20VT motors, don't suppose you can remember what the torque setting's are? The G60 manual quote's 30 NM + 180 degree's.
And I've just reread the manual and realised I misread the info, it says. "Connecting rod bolts can be reused only once when checking radial play with engine installed. After checking play mark each bolt on the thread side with a center punch to show the bolt was used once already"
So I guess I'm fine and to be fair to my mate he wasn't to know that this is a potential issue with G60's, he's built several MK2/3 GTI motors over the years with good results.
I'd have to check elsawin for torque settings as far as I can recall Most of the 8 valve bottom ends use the same setting.
Someone was really careless with head gasket then. A thorough coolant flush is in order.
having the sump Off is an eexcuse to fit a windage tray.
No worries, just curious to see if the 20VT setting are the same as the G60.
Yeah whoever did the head gasket was either a poor mechanic or one who's being pushed to do something on the cheap.
It's got suspiciously fresh looking coolant which goes hand in hand with the gasket being replaced, I'll be dropping it and flushing the entire system with a hose pipe.
Front end needs to come off anyways so I can do a proper job of the loom and PAS pipe work.
Ive got 30nm + 180` as well, hope you get it sorted I know the feeling ofhaving a car stuck for reasons beyond your control and other work needs to be done
Cheer's chaps, you expect some nonsense with a second hand car but having to rebuild an engine for the sake of eight little studs would be absolutely infuriating.
Fair play to my mate, he's a conscientious sort of chap and was gutted when I told him about the studs so he's spent some time asking round engine builders he knows. It transpires one can check if the studs have been over torqued and are shagged or if their still OK to reuse. Measure them, the new length is bang on 59 mm, anything over 59.5 is unacceptable, mine are all in the 59.1 59.2 mm range so are fine.
I'm bloody glad I dropped the oil, it looked like new on the dip stick and the paperwork suggested it had only done about 1K miles, but as it was over three old I changed it as a matter of course.
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I also have to rebuild an engine for no good reason which I REALLY don't have the time for ATM.
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