Build Thread: 1987 Scirocco 16V Garage Find

[scirocco16vobsessed]

Nice Intake Manifold. Where did you find such a fine example? The original paint did not come with a clear coat. It is old-fashioned enamel. A foggy look in the paint is oxidation, use a good cleaner to rub it out. Mine is still original, I use Meguiars to rub it clean, and seal and moisturize with good old carnuba wax. Keep it out of the sun as much as possible, and NEVER wash it in the sun, the water drops will BURN spots (from oxidation) into the paint. I learned this the hard way. Lots of rubbing after that episode. Don't treat original paint like todays paints, you'll f it up. Peeling clearcoat means it probably has been resprayed. The underside looks good, and so does the engine bay. I bought mine with 33k on the odo in 1989, and the So. Cal. climate has been good to her. Glad to see another rocco being restored. Feel free to PM me with any questions. Raffi at Eurosport is my bud, we go way back. Happy to help.

[JohnBarleyCorn]

Yeah, the intake came out very nice, thanks. Of course I cam across another one later that came on an engine I bought, so I'm practicing my polishing skills on that one right now. What a huge pain that is, but I hope it turns out nice. I'm thinking of leaving it a satin finish instead of a full polish...it looks better to me and it's less work. Now that you mention it, I guess the front end must have been resprayed. I'll probably leave the paint to the pros since there's a shop about a 1/4 mile down the road from me. I think I can get a cheapo buff out of them. They do good work.
Thanks for the advice. I actually have a car cover for this one so the sun should not be a big factor.
I wish I'd jumped on the brake setup you had, but c'est la vie.

[red16vman]

Well, I did it....bought yet another part for the beast. Got a deal on it and it's just too pretty not to go for it.

So THAT's what my old header was! I swear that looks exactly like what I had on my 16V when I bought it, but I don't remember any stamping on it. Regardless it was in terrible shape and later went to a stock manifold with a TT downpipe and exhaust. I remember that header made the exhaust sound pretty neat.

[MetalMessiah666]

Pete, gimmie that header!

[vwkid_Zach]

Darn good work so far..

I have never had a problem with autohausaz. They're just as good as anyone out there. Maybe you experienced a computer issue or something?? Anyways, keep up the good work! Looking forward to seeing some more. And put up a video of that exhaust you got going pweez?

[FaithInMkIII2.0]

Pete! Nice build thread man! I haven't updated mine since I have been driving the GTI around! Can't wait to hear this Rocco rip! I have to show this my buddy Paul, it will entice him to get working on his 84 Rocco! He lives off Little John road not far from you!

[Josh.Spenjet04]

[CäpeGrim]

[JohnBarleyCorn]

OK, so latest updates: last weekend I degreased the transmission (PITA) and it's sitting in the basement awaiting new seals and throwout and maybe anew pushrod just because.

Yesterday, I worked on degreasing the engine bay a bit to make it shine for its new powerplant.
Not sure when it's coming together...gotta harass my machine shop guy. He's only working like 12 hour days right now..what a wuss.

[JohnBarleyCorn]

Change of plans. The engine is still on hold at the shop, so I need to get moving without it. I'm dropping in the already built 2.0L 16V from another Rocco that I have. It's already had the work done to it and has less than 10k miles since, so it's really a no-brainer. I want to have it running in a couple weeks, so this is my only option. Engine came from a guy in NY who dropped in an even nastier built 16V with cams and all. Didn't need to, just has more $$$ than he needs. If the guy had a daughter I would have married her on the spot just to be in line to inherit his car collection. He's the same guy that GAVE me a VL Option 6 kit to convert an 020 tranny to a 6-speed.
Anyway, I'm gonna get started on this during the weekend and see where I can get to.

And the engine that's at the shop is going to be kept for a Fox or Quantum swap project using a longitudinal 16V setup from an Audi.

[Death Trap]

Funny thing is I sold a red 16v that looked just like your car when I lived in Masschusetts in the 90's
The guy bought it and the T-belt broke shortly after the purchase. The car I had came from the south (MD) so it was rust free and in nice shape at the time.

[Twinrocco's]

Getting the Scirocco ictch.. Maybe we will be seeing one soon? At Eurotech?

[Death Trap]

Ive had around 20 sciroccos over the years so its almost time to get another. I have my eye on a MK1 I know of.

[JohnBarleyCorn]

OK, it's been a while since I did anything, but I got the new motor/transmission mounts pressed in and I got to work on the front brakes. I love the fact that the brake hoses came free from the hard lines with little effort and the calipers still look good, so I'll clean them up and re-use them. I've got a good set of cleaned up and painted rears that I'll throw on if the original ones are shot, but I think they'll be OK. Also have the drilled/slotted/ cad plated rotors for front and rear ready to go. I just need to get some braided lines for the front and I'm all set. Front bearings are tight and smooth. Rears will get new ones. Got to clean up the engine and do a t-belt and tensioner on it. I'm going to just order the kit with new w/p from GAP. Why not? Also, I bead blasted the crank pulleys and re-painted them. I'll have to get a pic of the brackets, etc. that I've cleaned up. In the meantime, here are a few pics:
Engine bay:


Front brakes so far (cleaned up and rustoleum-ed the shields):

[JohnBarleyCorn]

I went down and took a pic. Here are the crank pulleys, the upper timing backing plate, the p/s pump brackets, rear caliper carriers, and the two pressed in mounts.


And the Scirocco will have a new home as soon as it's finished and road tested and all. My sister needs a second car and I convinced her and my brother in law to take the Scirocco and get rid of their POS Saturn instead of fixing it. I'll probably fix the Saturn and sell it for them. So I get to keep the Rocco after all! Well, kind of.

[greenenayr]

Massachusetts

[JohnBarleyCorn]

So this is the engine that's going in the car. It's out of a Scirocco built for Autocross, and the guy pulled it to install an even more built engine (rods, pistons, cams, heavy port/polish, etc.). This engine is stock but for some porting/polishing and has very low miles on it. And yes, it's a 2.0L 9A.
It sat in his basement for a while and it doubles as a woodworking woodshop, so there was plenty of fine sawdust all over it, but nothing to get into the head or anything. It was all sealed up and it had oil in it and it turns over like a dream and there's no weeping from the head gasket or the oil seals or even the valve cover gasket (which is of to be blasted and painted).


Some mild smoothing of the intake ports.

[Betty Humpter]

looks awesome! I miss my scirocco's!!! Good work!!

[JohnBarleyCorn]

I just went ahead and ordered a set of the silicone 16V hoses from Gee Bee. Red ones, hope that's a good choice. I like to have light colors on things so I can see oil leaks and such.

[JohnBarleyCorn]

Oh and I forgot to say I went ahead and installed the new sunroof seal. A big old PITA but next time I do one it'll be easier. I'm waiting on a bunch of parts from GAP (brake stuff, timing belt/tensioner, water pump, t-stat, rad fan switch, flywheel and PP bolts, etc). Engine and trans definitely going in next weekend.

[MickR]

Nice build - watching ya. "sunroof seal from Germany" - what is that source?

[JohnBarleyCorn]

I got mine from Germany, but now mk1autohaus or whatever (moogie on ebay) has them much quicker and not much more expensive at all.
http://cgi.ebay.com/ebaymotors/Gen-V...Q5fAccessories

[BryGuy888]

Nice build , in for the results

[JohnBarleyCorn]

Big day today. Engine got its new timing belt, tensioner, crank timing belt cog (with new bolt of course), water pump, & thermostat. Installed the pass side motor mount and the related tin and lower timing cover. Got the engine set in place with a jack for support along with the aforementioned motor mount. The mount is pretty much just keeping the engine balanced. The power steering pump and bracket is installed, the A/C bracket and compressor are installed and I'll add the alternator tomorrow. Also tomorrow, the clutch and the transmission will go on, if all goes well, which means the remaining mounts will also go on. Then the shift linkage and the exhaust and then it's just brakes and she should be pretty much ready.

[JohnBarleyCorn]

I'll have to wait to get the new silicone hose set...should be this week sometime. I'm hoping next weekend will be it's first test drive, but I'm sure something will come up.

[JohnBarleyCorn]

New clutch installed. Transmission installed. Holy PITA motor/transmission mounts. I forgot what a beach those are if you don't have about 5 different adjustments you can make to the tilt of the engine/transmission. But they're in and happy for now. Exhaust is next. Then brakes. Then button it all up and see where she stands. Pics tomorrow. I'm tired.

[JohnBarleyCorn]

And after the other 3 mounts were installed loosely....this freaking front mount! I hate it. Got it pretty close after some gentle pry-bar work all around the engine bay. I think a spacer behind the front mount plate would work wonders.
Is everyone else's mount angled as much as this? I seem to remember my old Rocco's mount being similar.

[RoccoRacer]

I don't remember mine being angled so much, but I did use probably 3/4" worth of spacer between the cup and the radiator support.

[JohnBarleyCorn]

Got the stainless braided brake lines today from the Canadian company. Paid $55 shipped through ebay and they look really nice. DOT certified, PVC sleeved, nice black connectors. I'm thinking it was a good buy. I'll post up some pics soon. Most of the kits I've looked at have been $110 plus shipping or thereabouts.

[JohnBarleyCorn]

Header is on. Looks awesome. Doesn't quite line up with the over-axle pipe, but I'll fix that up later. The new O2 sensor is installed in there too. Got the injectors all fitted in with all their new cups and o-rings and whatnot. The K&N is fitted into the airbox and the new Bosch fuel filter is installed with all new sealing washers. I must admit it's a way better setup to have those fitting up under the hood rather than under the car, where they rust away. I'm still waiting on my silicone hose kit to get here and I need to get a new axle flange seal (the black rubber disc from inside the flange cup), then I can put the axles in. My drilled, plated rotors that I had bought way back when turned out to be the wrong ones...too much offset. Then the ones I had for my other project from ECS turned out to be 9.4 instead of 10.1. I can't win. So I ordered a set of drilled/plated front rotors from a Canadian company (Silverstone) and we'll see if they are good or crap. For ~$55 shipped, I can't go wrong.

[JohnBarleyCorn]

Ordered the new knock sensor, all new belts, some oil filters and sealing washers, and new poly control arm bushings from GAP today. Should be here Thursday. The front brake rotors got here this morning, so hopefully I can get them in tonight with the new calipers and stainless braided lines and maybe the bushings too. Man, I want to fire this thing up! This weekend it will fire...

[prom king]

Looking great

[JohnBarleyCorn]

Got the front brakes installed. Rotors are raybestos brand that they drilled and plated. Better than the low end stuff from autozone by a long shot. I'm very happy with the money I spent. You can also see the Canadian braided lines in there too. Again, pleasantly surprised. I included pics of the installed injectors and the new fuel filter. I'm really hoping for a fire-up this weekend. I'm still waiting on the silicone hose set. Gotta check on those.

[JohnBarleyCorn]

Got the prothane control arm bushings, belts, speedo cable gasket, final drive seal, knock sensor, and oil filter w/sealing washer today from GAP. Also the set screws for the front rotors (I hate not having those and yes, I'll hit them with a little anti-seize.) I should be able to get the front end buttoned up today/tomorrow and maybe fire her up this weekend. Still gotta flush the tank and deglaze/desludge it if need be.....I have yet to look down in there.

[JohnBarleyCorn]

Alright. New oil and filter, the brake rotor set screws are in after chasing the threads first. The transmission is refilled with Redline MTL (I'll drain and refill the tranny in a few thousand miles again as the old oil was nasty and pasty black) and the speedo cable is installed with a brand new gasket. I replaced the one bad high beam and all is well with the lighting. The pass side cv shield is bolted to the engine block. The final drive seals are installed. Tomorrow I'll probably install the axles and maybe the poly control arm bushings. I need to torque the crank bolt as it's just snug in there right now. Then it's time to install the belts and then the hoses whenever they get here...