i said i'd do it, so that's what i'm gonna do.

I dont want this to be treated as a guide of any kind, nor do i want to hear about how you used this information to destroy your supercharger. This is not a guide, and shouldnt be treated as such, it's mearly a a series of posts that i'm going to make showing how I've dismantled my supercharger. Just incase anyone is interested..........

(if i make any mistakes please let me know and i'll alter it asap)

Chapter 1.....charger is off the car, sitting on the kitchen floor. not ideal really, usually i do it at work, on a piece of thick foam, on a bench.

The charger must be handled with care at all times! Very easily damaged!

looks like this....

still got the mounting plate on it, and the pulley I'm if lucky.

pulley needs to come off first chain whip and a 17mm socket is usually enough , pulley puller if it's tight.

removing the 13mm bolts holding the mounting plate on reveals this timing sprockets and timing belt(below).

Dont need to bother with the belt and pulley though at the minute. The outlet half of the charger needs to be removed first. Achieved by removing the six 5mm allen key bolts holding the 2 charger halves together(see below). Gotta use a good quality allen key sockey on a ratchet for this, a shit/knackered one will only round them off.

I'm sure there's a million ways that people separate the two halves of the charger, but this is how i do it........

With a set of small grips and one of the old allen key bolts screwed in, with the minimal amount of force, then with a plastic trim tool just around the very edges between the two halves.

The two halves must be separated without rotating. this is pretty easy once the sealant has been broken.

When two halves come apart some of the apex seals(long strips of sintered material that sit in the grooves) and apex seal springs(under the seals, in the grooves) may drop out. Apex springs must not be damaged!

This is what can now be seen.........

At this point it is very easy to damage brittle parts inside! Gotta be handled with extreme care.

Edited 13 February, 200719 yr by richg40

Hi Richg40

Nice one

Cool Iv been thinking of doing this for some time now. So were do you get your seals and PTFE grease from? I have seen kits in Germany but seem a bit expensive for what you get. And a PSD rebuild is £350 as I remember from last time so…….. but any way iv had my G for 2 1/2 years now and I like doing thinks my self now.

Thanks JAY

When i rebuild mine I use NAK seals, the original apex seals and FAG bearings. The seals and apex seals can be bought from the likes of SLS tuning or gladerseite etc etc. But the bearings can be bought from any decent bearing supplier like Midland Bearings quite cheaply, but i think either the large bearing in the displacer or the one on the main shaft in the outlet half are quite expensive.

As far as grease goes I dont and wont use PTFE but that's entirely up to you. If i remember right Kluber Nosol GBY 2 is the correct name for the grease, about £90 a kilo in this country or like a fiver for just enough off German ebay.

Edited 13 February, 200719 yr by richg40

When i rebuild mine I use NAK seals, the original apex seals and FAG bearings. The seals and apex seals can be bought from the likes of SLS tuning or gladerseite etc etc. But the bearings can be bought from any decent bearing supplier like Midland Bearings quite cheaply, but i think either the large bearing in the displacer or the one on the main shaft in the outlet half are quite expensive.

As far as grease goes I dont and wont use PTFE but that's entirely up to you. If i remember right Kluber Nosol GBY 2 is the correct name for the grease, about £90 a kilo in this country or like a fiver for just enough off German ebay.

Thanks mate.

Do you have the boost mod done because i have and i use PTFE in it to lub it up. But psd use that stuff (Kluber) and PTFE. So i think ill give it a go. Do you think it will be worth doing the bearings as IV done 15000 on them?

JAY

Edited 13 February, 200719 yr by JAYG40

15000 miles aint exactly alot for the bearings, but this depends on what size pulley you're using and if you've got a heavy right foot. I really dont want to get into giving advice, but i dont mind giving my opinion. At 15000 miles hopefully your charger wont need servicing, but if it were mine i'd just give it a good clean inside and regrease.

Next step is to remove the displacer.

The circlip that can be seen in the picture needs to be removed (circlip pliers from Halfords). Then the balance weight can then be removed (slides straight off). I've not yet come across one that's tight, but if i did i wouldnt force it, best left soaked in SAS or WD40 or equivalent for abit. see below.....

Once the weight is removed the balance weight key can be seen.....

This can be removed with some side cutters.....(again if tight, best soaked)

Then the Displacer can be removed. No screwdrivers involved here, plasitic trim tool I find is essential to avoid scoring. The Displacer must be removed uniformly without rotating. I find it best to lever at these points very gently........

AND

At this point the internal surfaces and apex seal grooves can be examined for wear and damage.

Edited 13 February, 200719 yr by richg40

although i've never done this before, i'm liking what i'm seeing seems fair simple up to this point (i imagen its going to be abit more complicated) but how long has it taken you to get so far, like an overall time so far?

i took these pictures of a charger i stripped about a month ago. time so far? 15 minutes or there abouts. obviously not including the time taken to take the charger off the car.

i took these pictures of a charger i stripped about a month ago. time so far? 15 minutes or there abouts. obviously not including the time taken to take the charger off the car.

haha, in itself, getting the thing off the car can take longer than that!

cheers

haven't had time to do this this week. will add more tomorrow afternoon.

did you ever do any more with this? or have i missed the thread- had it book marked sorry :)

discontinued due to lack of interest.

gutted ! makes interesting reading and pics good for references

did u ever get any further? interested?

did u ever get any further? interested?

I'm interested too....

Yeah, c'mon... Carry on with it :-D

shame this never got finished

maybe someone else could finish it off?

It is a really intresting thread you started here mate .

Try and get it finnished .

Alot of people ownt of seen the inside of a G40 charger and not be aware of how they work and will definatly not know how to refurb them .

This post is extreemly informative and it would be quite gutting to not see the complete produdct .

i got some pics of inside mine if anyone wants to see them, not sure of anything else though, lol. wanna see how to rebuild them, would be very very useful

should have been finished off !!!!

Surely there must be someone who can continue from where this left off? It must be an incredibly useful reference point for those who own G40's at the moment, especially with the demise of PSD. I'm sure there are a couple of G owners out there whio DIY service their chargers - i seem to remember hearing PeteG40 did, though i may be well wrong.

A shame to let info like this disappear when the owners sell up and move on.

Ok, ok. I'll try and get some more up over the easter break, but i aint making any promises.

Ok, ok. I'll try and get some more up over the easter break, but i aint making any promises.

Nice one. You know you want to.

cool matey, cheers, would be a good read

Please please please finish the thread off, I really would like to be able to do this myself properly without lining Jabbasports pocket :)