Some pics form the initial tear down:
In August 2007 my car, a '92 VR6 blew the head gasket a few days after turning the boost up a bit. It was really just a matter of time and I fault the stock gasket with 168k miles on it more than the added boost.
I decided to tear it all apart over the winter and rebuild it with a bunch of "while you're in there" go fast and maintenance parts. It's gotten a little out of hand since that day in August. A lot of work has been done over the winter, so I'll do my best to back log most of it and then post updates as I get this thing back on the road by June 7th, 2008.
Admittedly 2 wheel smoky burn outs are less cool than 4 wheel smokey burn outs - but they are decidedly better than one wheel smoky burn outs and clutch smoke.
Tearing apart the transmission for inspection of gears/syncro's, installation of Peloquin LSD, and tdi 5th.
transmission fluid really is nasty stuff.
In order to insure the diff was properly shimmed I put everything back to together for a test fit.
Shift forks installed, I had a hell of a time with keeping these suckers in their place until I realized you're supposed to (per the Bently) have the tranny tilted at a 45degree. Presto!
Almost no parts left!
Authentic VW "Sealing Paste"
Almost fully assembled.
The size difference between the TDI 0.75 and the stock 0.83 is surprising noticeable.
At this point the races checked out and were with in spec to the original factory installed shims. I hear this is common when you have a matching case, but its always good to check. I ran into a probable however in that the gears were binding and the trans wouldnt spin freely.
After taking this thing apart 4-5 times I realized the pinion ring was installed on the diff upside down. A quick fix, put it back together again (pretty much an expert at this point) and every thing was right as rain.
A few days of scrubing, some time with a pressure washer, 6 botles of degreaser and I had the case looking like this:
Some time around this point, after getting the Trans figured out I ran out of momentum and got distracted with a few other projects over the winter. Over the memorial day holiday I got it in my head that I might actually get this thing done in time for the first big show here in MI.
Took apart the head to check for flatness (for lack of a better word), just in case it had warped from the blown head gasket. And did manage to take a few more pictures:
I checked it with a straight edge and a feeler gauge, and couldnt find a single high or low spot. I wasnt too surprised here because the car never had a chance to over heat.
New Parts, Autotech 13lb flywheel, new clutch and timing chain kit:
The new head gasket/spacer set up will drop compression from 10:1 to 8.5:1. The gasket is comprised of a two piece mk4 metal gasket that is split and then sandwiches the stainless steel spacer. You want to spray the two gaskets (not the spacer with the permatex high temp copper gasket stuff.
New timing chains installed. The head is bolted down using ARP fasteners. Torquing order is same as stock (basically just diagonally from the center out) but the stronger studs can with stand a ton more torque. We stepped it up from 23-49-65-80 ft lbs.
While doing putting the chain covers back on I ran into an issue when installing the upper chain tension. My motor is out of a 96 Jetta, so I have the plastic valve cover and the dual timing chain. This being the first time Ive done the chains on the car, I ordered the new style chain kit-recommended for better durability and ideal for the dual chain setup (also cheaper). The only thing that wasnt back wards compatible with the new timing chain kit was the upper timing chain tensioner bolt. Pictured here is the full chain kit, the tensioner is the large brass bolt in the middle.
The new style upper chain tensioner doesn't thread all the way into the early style upper cover. The problem lies in that the new style cover is threaded all the way through, while the old style (the one i have) isnt threaded all the way. Apparently 92 distributors are some of the only cars to get the "old style" covers - which is what I have to make the new '96 motor work with me obd1 distributor setup.
Not being able to find a 22m x 1.5 Tap locally on the Saturday of memorial day weekend, I oped to port out the back end to get the new style tensioner bolt to thread in all the way. Vortex recommends forcing the new bolt in a 1/4 turn at a time using "lots of oil". I wasnt comfortable with this so I went with the Dremel and never looked back, I only removed (max) a few cubic mills of Al from the back side of the case.
Next up, the valve cover, lightweight flywheel and the clutch assembly.
Modified by corrado-correr at 5:42 PM 5-28-2008
Monday I was determined to get the transmission in. Here's the transmission lookin' funky fresh on the floor waiting to go back in his home.
Ryan and I struggled with it till it almost landed on my head, then we called around for an engine hoist. Ryan is crazy:
Engine and transmission are in and bolted securely to the motor mounts. The shiny trans looks so out of place in the dirty ass bay.
Oh, and we found a turtle that day... sweet!
Modified by corrado-correr at 5:41 PM 5-28-2008
Brand new thermostat housing and all new temp sensors. New one on the left, old one on the right.
I took the front cross member off sanded it and hit it with some rustolium. Also painted the front motor mount. Installed the thermo housing and new billet crack pipe.
The obligatory "Fuke you old crack pipe!"
Lower intake manifold, new gasket, fuel rail, 4.0 bar fuel pressure regulator, and 30# injectors.
Thats it for tonight suckas.
Quote, originally posted by gunnr0991 » There is no way that tranny isn't P-shopped.... how the hell did you get it so damned clean?
here's an intermediate step (I was orginally going to polish the whole thing untill I realized it was a ton more work that I wanted to do ):
Quote, originally posted by Gilboyto » that intake manifold is SICK!!!!!!!!! OMG makes me want to paint my Schimmel. Who did that for you just a local shop?
looks polished and painted. looks tight tho.
Horology, Renovations, Home, Auto, anything. You need it, I can do it. If I can't, I know who can! I'm here to help! Ask me anything, ill do my best.
Today when I woke in the morning, and said to my self... "Self, you should take the day off to work on the Corrado" and so I did. As luck might have it I received a package in the mail today so it was pretty easy to decide where to start working.
An aluminum (with serviceable ball bearing) belt tensioner pully, and a metal (to replace the melted plastic piece) shift linkage, all from Gruvenparts.com.
Here you can see the old brittle melted linkage along side the new piece. The Gruven piece also reduces the side-to-side.
Then all hell broke loose and there was a lot of cursing and swearing. "****", I said. the new linkage housing doober I bought (from the dealership, using my VIN number) was the wrong part. Notice how the yellow cable doesnt line up at all!
I decided to put the old one back in even though its ****ed up on the top there. but at least this way the cable line up. I also tried to mess with the adjustment, but failed with out a helper to shift inside while I adjusted in the bay.
Stainless exhaust studs make baby jesus cry with joy and laughter:
Exhaust manifold all bolted up:
And right before it started raining, I got the turbo and waste gate in!!!!! WOOTshhhhhhTTT!
Modified by corrado-correr at 7:18 PM 5-30-2008
Has no one here put a Kinetics manifold on while the engine was in before??? not to sound like too much of a needy bitch, but I could use some words of encouragement here.
Here's to a nice refreshing beer or 6 after a good days work.
Quote, originally posted by Lanceevox » soo... how is the gruven shift linkage? I was thinking about ordering one up.
I haven't really finished adjusting it yet, nor have I driven it yet, but man does it reduce side-to-side. on top of the diesel geek short shift kit I have I gotta tell you it might actually take some getting used to - its that tight now.
From an installation stand point it fits great, and it replaces the crappy plastic part that you can see from the pic was practicably melted into swiss cheese.
This is probably the first show I've ever went to with out bringing my camera. I only slept 2 hours the night before to get everything driveable, and in all the hustle to make it there forgot the camera.
from the vortex galleries: