G-charger - removal and refitting

Fuel system: multi-point injection models / G-charger - removal and refitting

General information
1 The G-charger develops its maximum pressure at full load and so cannot be tested with the vehicle stationary. It is recommended that the boost pressure is measured by a WV dealer, using a rolling road. However, if this is not possible, the measurement may be made as follows.

2 Connect a vacuum hose T-piece in line with the vacuum supply to the fuel pressure regulator. Route a length of vacuum hose from the T-piece to a pressure test gauge in the cabin. Close the bonnet, ensuring that the vacuum hose is not trapped. Enlist the help of an assistant to hold the gauge and read off measurements from the passenger seat.

3 Drive the vehicle on a strip of private road (not the public highway) at full throttle in second gear whilst simultaneously depressing the footbrake to maintain an engine speed of 4000 rpm. Have your assistant record the maximum boost pressure indicated.

Caution: Do not maintain these driving conditions for more than 10 seconds.

4 Compare the measurement with that listed in the Specifications. If the boost pressure is low, check the tension of the drivebelts (as described in Chapter 1) and make sure that there are no leaks or blockages in the inlet system, before condemning the G-charger.

Removal
Warning: Do not run the engine with the G-charger air inlet hose disconnected; the depression at the inlet can build up very suddenly if the engine speed raised and there is the risk of foreign objects being sucked in.

Caution: Thoroughy clean around all oil pipe unions before disconnecting them, to prevent the ingress of dirt. Store components in a sealed container to prevent contamination. Cover the G-charger air inlet ducts to prevent debris entering and clean using lint-free cloths only.

5 Remove the screws and lift off the G-charger cover plates.

6 Remove the auxiliary drivebelts (Chapter 1).

7 Slacken the clips and detach the air inlet and delivery ducting from the G-charger ports. Cover the open ports with plastic sheeting secured with elastic bands, to prevent the ingress of foreign material.

8 Slacken and withdraw the banjo bolts at the oil supply and return unions. Recover the sealing washers and discard them - new ones must be used on refitting. Plug the open oilways to minimise oil loss and prevent contamination.

9 Slacken and withdraw the G-charger mounting bracket bolts, supporting the unit as the last bolt is withdrawn.

10 Remove the G-charger from the engine bay together with its mounting bracket and the drivebelt pulleys.

Refitting
11 Refit the G-charger by following the removal procedure in reverse, noting the following points:
a) Ensure that the air inlet ducting is completely free of debris, before refitting it and securing the clips.

b) Use new sealing washers when reconnecting the oil supply and return unions; tighten the banjo bolts to the specified torque.

c) With reference to Chapter 1, refit and tension the auxiliary drivebelts.