new car gt g40 running 150 bhp psd mods servicing and maintance help

[dub-disaster]

hi all,
    i am new to this g40 game i recently purchased a 1991 mk 3 polo gt with a g40 engine in it the engine as had a few mods like i belive the boost reciculation mod toothed belt mod smaller pulley and chip it revs up to and over 7000rpm prusucing lovley power, but i am new tot this and i want to keep the engine running sweet so wat sort of maintenance do i need to do to it how regulary does it need servicing? do i need to spray ptfe grease at the in the charger and how often. also it has had a seprate mocal oil catch tank a feed for the charger i assume? it hasnt been service in a year but has only covered 3k since its last service dont know when the cam belt was last done so i have booked it in to have and oil change cam belt and charger belts all changed. i intend on running this car as my daily and drive 100-150 miles a week so i want this car to be reliable and dont mind servicing it but i just want to know what i have to do . it has had the charger rebuilt 9k ago is there any garages where i can take it they can look at it and tell me exactly what ive got and how to keep it running sweet i live in the south west of england in yeovil somerset so somewhere reasonably close would be brilliant

all help appreciated as i now love this car but dont want to break my increadble bit of kit

[scotsjohn]

Hi Mate,
        you won't be stuck for advice here, so I'll start with the following:- DON'T hit the rev limiter too often, oil pressure spikes and blows internal seals in the charger. Regular oil changes( a lot of people change it at 3k intervals) are the name of the game. The engine itself is pretty strong, but cleanliness is next to godliness for reliability. Keeping electrics clean and earthing points in particular is worth while. Maybe a new water pump while you're getting the cam belt changed . If the boost return pipe is disconnected,the Mocal tank might be for collecting the crap that normally gets fed back through the charger. If so it will need cleaning from time to time. Alternatively you may have a stand-alone oil feed to the charger. MAKE SURE WHICH BEFORE EMPTYING THE TANK.Monthly spray of PTFE. Charger service about every 30k. Hope this helps and welcome to the wacky world of G's

[dub-disaster]

well thanks for the advise mate ive taken it all in,
i think it is a stand alone oil feed thats what i was told about it any way, what type of oil should i be using for this as its running a little low ( its very very clean) and how often does this need changing . As for hitting the limiter ive reved it up to about 7 ish and still havnt herd the limiter cut in so im not to sure where it is ! but im sure it isnt far of i have driven it hard for a day or so ( hope i havnt damaged anything ) but i shall ease of it now and i dont drive it every day mainly at weekends. as for the oil change what type of oil should i  be throwing in ? how often for spark plugs as it had a new set of plugs a year ago but has only covered about 3-4 k last year ? how much roughly would i expect to pay for a changed water pump or should i wait till the pump goes ( not got cash coming out my ears). what type of ptfe grease should i be using does it matter, and where can i get a good stock and how much do i apply each time ? Finally i was told by the previous owner that the charger was rebuilt 9k ago by psd themselves but with the folder of reciepts i couldnt find a recipt for any of the work done by psd so have no proof that the charger was done should i bite the bullet and leave it or get my wallet out and have it rebuilt now if so where's the best place to have this and all the other stuff done in one go then i can  just sit back enjoy the car and change the oil myself.
Once again sorry for all the questions i just wanna keep this car running nicely

[PeteG40]

1. standalone takes very thin oil - hayesey used compressor oil
2. spark plugs normally last 20,000 miles as they are platignum
3. if you have the timing belt done - do the water pump, it acts as a tensioner. If that goes the timing belt goes/. Water pumps are about £35 exchange from vag.  Expect to pay £50 for parts and probably £100 for labour
4. PTFE - be careful what you use, as some stuff can rot seals
5. oil 10/40w decent quality semi synthetic with a filter
6. a charger rebuild can be done by g-werks or jabbasport for between £350 - £500

[hayesey]

if it's a stand alone tank then there'll be at least two pipes coming off it.  One will go to a pump (assuming it's a PSD kit then it'll go to a square solid state fuel pump) and the return pipe to the tank comes from the charger outlet on the supercharger itself.

If it's a catch tank then it'll normally just have one pipe coming from the oil breather on the back of the engine block.

If it's a stand alone then I'd probably change the oil when ever you change the engine oil.  At least every year, ideally every six months/5000 miles (whichever comes first).  You need to use thin oil in it because the fuel pumps used aren't really designed to flow oil, as Pete said when I had a standalone on mine (only reason I dont now is because I have a turbo instead of supercharger) I used compressor oil in it mostly.  Initially I used some thin fully synth engine oil.