Step By Step DIY G60 Disassembly (lots of pics)

[g60racer]

Pics are still hosted and working fine... check your browser settings or try a different browser!

[slvrarrow]

BUMP..

[ahbroody]

bumpin

[g60racer]

pics working again, updated the links to hostdub

[dubbernutter]

might be a repost, didnt read all the posts, but boy would i like to see the assembly process!!

[g60racer]

Assembly process is basically the reverse of this post, but including Red Line assembly lube on all the close fitting parts, Kluber grease on the displacer, and anaerobic sealant on the sealing surfaces of the casings when you put them back together. I also use antisieze compound in all the woodruff keys so they don't get permanently stuck, want them to be able to pop out easily when it's time for the next rebuild.

[CHRGD_MK2]

What about telling people to line up the timeing marks on the cogs??

[Schnell-Corrado]

bump, great write up and pics!

Don't be afraid to try it yourself dudes

[g60racer]

Quote, originally posted by EUROJETTA8V1991 »

What about telling people to line up the timeing marks on the cogs??

Oh yeah, line up the timing marks on the cogs.

Or if you have TEC or other aftermarket cogs, line them up so the woodruff keys are both pointing the same direction.

[kittylicker]

got any pics of putting one back together ?.....lol

[poorman]

that was beautiful....i cried, i laughed and i cried some more...

[g60racer]

Thanks.... just brought my charger porting thread back up to the top too... took me a frikkin hour just to get them all back hosted again and the post edited.

[kittylicker]

any pics or intructions on putting it back together?

[oRz-Motorsport]

Quote, originally posted by KompressorKanada »

...there are 3 different generations of displacers (actually 4... but I'm not getting into that)...

How is that four styles?

[Texas-A6-4.2]

Ditto!

Some folks will also find that the ring, which has the timing mark on it, will come loose and just spin freely.

If this happens do just as G60racer said..... Line them up at the 12 O'Clock position and you will be OK.

[g60racer]

Bump for the newbies.

[g60racer]

ttt for newbies!

[g60racer]

yet another thread that used to be stickied and in the FAQ, and for some reason isn't anymore.

[xxBlack_Heart_Valentinexx]

NICE POST!! Need one on pulling bearings now...I read they come out by hand if you dont mind getting oil all over you or just use a small bearing puller.

[raider352]

Quote, originally posted by JustA1s »

Damn, I thought maybe you were going to show bearings coming out. I've got like 2 I can't figure out.

nope! bearings and seals are the not so easy part. once we get that kind of info well then anybody could do a rebuilt. i know i could.

[xjronx]

Quote, originally posted by raider352 »

nope! bearings and seals are the not so easy part. once we get that kind of info well then anybody could do a rebuilt. i know i could.

Which ones are the problems, i'll show you how i did mine.

[raider352]

do us a big favor, the g60 humankind needs a tutorial of seals and bearings removal
look at it this way. you'll have a beer (or beverage of choice) wating for you in every state your post have been used to do a rebuilt!!!! SC here.

[Camp]

Got my beer supply ready

[scottamus36]

I'll send a 6 pack of anything German you like for a quality tutorial on that!

[1badVWhabbit]

Second that, I'm in Mass...I can do this, i am very sure, I've rebuilt turbo's...But they are more common....The ladder get's my hair to stand up a bit...anyone out there that wants to play with me and this G-ladder i am getting?

[mr.yuck]

Anyone have opinions on rebuild kits out there. What rebuild kit options are out there!?...

Does anyone want to share what they wished there kit had or what they wished in there kit was built better?

seems like this is turning into a faq so lets make it complete

[g60racer]

bump for noobs

[jvillagran2000]

i think the pics expired,I'm getting red x's

[Whitsend]

Any chance of recovering the pics from the original post?

[bluidgti]

yeah i haven't been able to get pics on this thread for weeks. no matter what puter im on.

[auberG]

Yeh more pics would be awesome!!

[iv38]

i saved this page (pics included) in pdf format when it was originally posted - if you need pics just message me your email address and i'll send it over...

[35i 2000]

is the pdf still alive?

[iv38]

There's been quite a bit of interest for the original pics. So here it is, along with some extras...

a link to the pdf i made of the original post

+ a well-written g60 charger rebuild guide from another site

+ g40/60 charger patent application filed in 1989 prior to manufacture

hope you find it helpful. cheers

[SYNYSTAGLX]

G60 newb here....
Damn good writeup Brendan, still have the PIX you captured for this thread? I'd like to print this out and have around, since I now own your G60 motor.