You can't tease us like that, must post pics!!!
Well, I figured it was time to start a build thread.
I bought a 1991 G60 Corrado last fall, I tried to get the motor running well for far too long, but in the end there was just too much wrong with the motor to repair when I could put in the TDI I had in my garage!
The motor I am using came from a '04 jetta, it is a BEW 1.9 PD TDI
Of course things could not go smoothly with the motor
There was a piece of broken plastic from the intake flap motor in one of the cylinders, so off came the head.
I cleaned up the motor, and am in the process of putting in the new head gasket, water pump, TB and tensioner.
Next up is to make the rear mount clear the turbo, then on to finding an alternator bracket.
Pix will come soon, once I get a new card reader.
P.S. I need an alt. bracket, anyone know of one for sale, or if one from a gas motor can be modded to fit?
G60ing has done 2 of these swaps into both G60 and SLC Corrados. The SLC had an ALH motor in it. May want to look into his build threads for ideas As much as I like the idea, I can't bring myself to put a TDI into a Corrado. Good luck on the project just the same. Any plans for upgrades to the motor??
Army OIF Veteran
Sorry about the long delay on getting pics, have not had time to work on any of my 'Dubs :-(
anyways, here is a pic of the Grenade 60 shell it is going into
the BEW motor, now that I got the head bolted back on
and the custom rear bracket
I am now working on the wiring stuff, since I still am waiting for the timing belt parts since I got suckered by prothe. wasn't paying close attention when I ordered the first kit.
Anyone have an alternator bracket for a PD?
Strengthen up that rear motor mount G60ING did exactly the same on his TDI SLC and broke it in half! Either weld a plate over the hole, or make a steel L section to reinforce it. Or something
100hp is 'mm ok' in a 'rado, but you will soon want more Plenty of bits over here in Europe to get massive torks from those things, especially if you go for a VNT20 off the 2.5TDI
Wiring diagrams on the way
Throw an Audi engineer down a hole with a ladder and he will fashion a shovel from it and tunnel his way out
I'd build a solid one or make one out of steel if I had to do it again. You could just build a really powerful motor and then it won't break...mine didn't break at WF when drag racing but then again the track was not prepped very well. It broke at a local track that was prepped for 8sec cars. I experianced wheel hop because I had so much traction
don't worry about the bracket then That was my same thought process and everytime I went to the track I knew the risk I was taking. Hell I made two brackets when fabbing them.
Modified by G60ING at 8:13 AM 4-30-2009
Hi reworked the rear mount on my boys car and it's held up fine with lots of abuse.
here is a pic
05.5Jetta TDI stg2 DSG, 00Jetta TDI 6spd stg6 race, 99.5Jetta Rocket Diesel stg5 ARL-PD150 6spd 2260, 02Jetta 1.8T stg2 GT28RS auto, WinOls, CMD, Byteshooter, Optican, etc. 2003.5 5.9L Cummins QCLB 4x4 Blue Monster, 00Passat1.8T, other tdi's: 97J, 98J, 99.5J2x, 92 Corrado Stg1 vR6, 00-C5 6spd - EFILive, HPTuner, Diablo Sport!
"DIESEL TUNING PROFESSIONAL" 1-5-3-6-2-4=;-)
Thats a great idea for a reinforcement! I will make sure I get that done before I get the motor in the car.
I finally got the timing belt put on.
and I got my EGR block off made (I just cut one of the EGR pipe flanges off, and welded the hole shut)
Now I am looking for a AAZ manifold to replace this with because of how complicated the original manifold is with all the valves
Sorry about the lack of updates, I have not had time to get any work done on the car till this weekend, although I have tracked down some of the parts I need, and I think I have most of the wiring done.
This weekend, I got the manual shifter swapped in, I swapped in the heater box from a MK4, moved the wiring for the MK4 stereo so I could rip out that AKTIV crap Welded the DBW pedal bracket to the pedal cluster. I have some pics of the pedal cluster here:
The mechanical part is the easy part. Getting all of the wiring installed and looking the way you want it with an instruument cluster is where the real challenge of the swap lies. Keep the progress coming