Progress on the Corrado

[wed3k]

nice job!

my buddy who has 3 tdi's was saying that it would be pretty easy for any 96-97 tdi to swap in considering the intercooler and air box are in the same place.

but mine's staying g60, tdi swap in a caddy is what im shooting for!

[girdwood]

nice job!

my buddy who has 3 tdi's was saying that it would be pretty easy for any 96-97 tdi to swap in considering the intercooler and air box are in the same place.

but mine's staying g60, tdi swap in a caddy is what im shooting for!

Thanks, man. That's what I was thinking too, but apparently there's no room for the boost tubes. Everything from the ALH accessory-wise is in there, PS pump, AC condensor, etc. I'll have to dink around with it when I get back. A caddy TDI would be pretty awesome. I decided to do the Corrado because I've already put too much time and money into it, and haven't driven it hardly at all (other than 2 cross-country trips). I wanted something fun and reliable (didn't think the Lysholm fit both of those; it has already siezed on the new owner). And once I get out of my current profession, I'll be using it as a daily (all brake, suspension, mechanical pieces have been replaced; it's essentially new, just like my Mk1).

[G60ING]

Having a little experience in this arena I would say the ALH is the superior engine and ECU but for wiring it I think the ALH is the worst. I would suggest that you use the B4 wiring harness/ECU to run the ALH. It has been done before and is pretty straight forward. The wiring will just plug and play. Then you can use a B4 pedal cluster and B4 instrument cluster. You will need to modify the B4/Mk3 ECU to run a VNT and if you want you can use the mk4 MAF too (its superior). If I hadn't stumbled upon a killer deal on a factory external waterpump TDI Longblock I would have gone down the route of the ALH.

Here are a couple threads where people have talked about the ALH with the B4/Mk3 wiring:
http://forums.tdiclub.com/showthread.php?t=259005
http://forums.tdiclub.com/showthread.php?t=318379
http://forums.tdiclub.com/showthread.php?t=185550
http://forums.tdiclub.com/showthread.php?t=280711

Keep up the good progress

[girdwood]

Having a little experience in this arena I would say the ALH is the superior engine and ECU but for wiring it I think the ALH is the worst. I would suggest that you use the B4 wiring harness/ECU to run the ALH. It has been done before and is pretty straight forward. The wiring will just plug and play. Then you can use a B4 pedal cluster and B4 instrument cluster. You will need to modify the B4/Mk3 ECU to run a VNT and if you want you can use the mk4 MAF too (its superior). If I hadn't stumbled upon a killer deal on a factory external waterpump TDI Longblock I would have gone down the route of the ALH.

Here are a couple threads where people have talked about the ALH with the B4/Mk3 wiring:
http://forums.tdiclub.com/showthread.php?t=259005
http://forums.tdiclub.com/showthread.php?t=318379
http://forums.tdiclub.com/showthread.php?t=185550
http://forums.tdiclub.com/showthread.php?t=280711

Keep up the good progress

Thanks, man. We're using the ALH ECU and making the harness between the Corrado and Mk4 one (had one from taillight to headlight, and everything inbetween). Using the Mk4 fuse/powerblock setup, as well (pretty cool addition, I think). The guys doing the wiring for me are pretty good at it; although they have said it's quite the headache. They just introduced a new project they've been working on called digisquirt (seen here http://digisquirt.info/wiki/index.php/Project_Overview ), so I have full confidence that everything will be above par. I don't remember what pedal I got... it's been a long time since I sourced the parts and did the research. My wife is kind of the middle-man between me and my buddys right now since communication isn't the greatest, nor do I have a lot of time when I do get it.

[girdwood]

The wife picked up the GLI a few days ago, got the TB/WP done and driving it with no major issues as of now... hopefully it stays that way.

[girdwood]

The wife picked up the GLI a few days ago, got the TB/WP done and driving it with no major issues as of now... hopefully it stays that way.

Well, so much for that... clutch is shot, and the differential bearings are on their last legs Anyone have an O2M for cheap?

Engine is back out, the engine bay is pretty much done; just waiting on some heat-shield material to put on the firewall, then it gets put back together. I have pics, but the internet here is incredibly slow, so I'll post them later.

I haven't really looked into bumpers for the Corrados too much, but I do want to replace them. The body work done on them was just enough to make the presentable, I didn't want to spend too much time/effort/money on them because I do eventually want to replace them. They are warped, damaged, etc. What are some good quality bumpers that are some-what OE (I don't want anything extreme, it is a daily driver)? Or maybe a reputable place to get factory re-pops?

[girdwood]

Internet is running slow as hell right now, so I can only upload a couple. Here's a couple before shots:

[girdwood]

More:





























And for kicks and giggles, a picture of me and my guys



Only a couple weeks left!

[girdwood]

Well, looks like we're going to have to wait to make the AC functional. I need to figure something out for the intercooler, and then once that is done I'll have the lines made for the AC. I'm looking into some AWIC, has anyone had good/bad experiences with any certain ones?

[ajhvw93]

After seeing the above pict. I can see why you would want to keep AC. Look up Mike Dasbeast 3.0

he may be able to help. Thanks for your service to our Nation

[girdwood]

I'll have to look into that screen name; has he done one of these swaps before too?

And thanks; happy Veteran's Day weekend, everyone haha

[ajhvw93]

I thought he may be able to help you with AWIC

[rollercoasterracer]

Cool, thanks! I just shot him a PM.

So with the newest addition to the family needing a transmission (O2M), I'm buying a used one with everything needed to swap to do an O2M swap. The plan as of now is to sit on the tranny that needs a rebuild for sometime before fixing it and putting it in the Corrado and putting the 'new' one in the GLI.

ha... just realized I'm signed in on my old handle; looks like I never logged out on this computer, and it hasn't been connected to the internet since I left for deployment.

[girdwood]

So with being state-side, I thought I'd be able to help out with the swap. I've made it over there twice I had a lot more going on than I had anticipated on the way home. But, we were able to discuss some issues that have been giving him problems, and I'm hoping you guys have some insight:

1) With the 02J, we noticed there were differences in the box/shifter cables (I guess NB and then Golf/Jetta). Now, are there differences in the master cylinder and vehicle speed sensor as well? We're trying to figure out which VSS/MC to use, or if there will be a difference.

2) For the TDI gurus, the EGR delete; possible or recommended with the Kerma PD150 kit?

3) Can anyone with a late ALH (such as this one) take a picture (or have pictures) of the routing of the coolant hoses? There's slight confusion on the thermostat outlet hose/overflow.

4) We have a Mk3 VR K-frame (or at least it's what I thought it was) with Mk3 VR motor/trans mounts. The passenger side seems to sit extremely high; the EGR valve (on top of the intake) will not clear the hood. Are we missing something? It just doesn't seem like it's sitting correctly, but we have no TDI or decent pictures to compare.

5) Reverse light switch, we need one of the square styles, what would that be off of?

6) MAP/IAT: I'm missing that part of the intake piping (as well as the sensor itself). Are there any differences between all the ALH MAP/IATs, or are they all the same (the connector I have for it is a 4pin flat)?

7) The coolant line going to the charge pipe... I plan on running no intercooler (for the time being; once she's running and driving good with no other issues, I'll start doing slight modifications such as an AWIC; once the money flow is more predictable/stable again ). Can anyone give me some input as far as the significance to that coolant line? To our understanding, the engine will not warm up at idle, and this is meant to help that process, no?

I understand the majority of these questions could be answered with research; which is what I'm trying to do. But, life is getting in the way of this project and I'm currently extremely short on time. Any help is appreciated And there are many updated pictures; I will try to get some ASAP. In the meantime, here's some nostalgic ones from one of my cross-country trips with the car









On a side-note, we've decided (after much debate) to keep the Mk3 and sell the Mk1. So if anyone is looking for a rebuilt 1.6D (NA) 5spd Mk1 (literally everything mechanical is new; no joke), send them our way! And the Mk4 is still a POS that continues to break away at our checking account for new parts.

[GT TDI Golf]

The shifter box/cables will be different depending on the color of the shift weight on the tower of the trans. (black or silver) It depends on the year of the swap you did. Early models have the black one and I think it's pre 2000. Not for sure but my '01 has the silver shift weight. I have an EGR delete done on my TDI. Just takes a little longer to warm up and will cool down quickly if it just idles with the heat on are the only things I noticed. Sorry I can't really help with the rest. Glad to hear you're back safe! Never made it to Afghan-land and glad for it!

[girdwood]

Thanks! We noticed when the cables I had didn't mate with the rest of it; found out I do have the early 02J. Which, now, we're hoping wasn't a difference in CVs, otherwise we'll have fitment issues there, too. I'm thinking I might wind up doing the EGR delete just to avoid the fitment issues with the hood... And thanks, it's good to be back again. That was my second time in afghan-land; possibly the last (at least in this uniform).

[Noah@VerdictMotorsports]

More:

[G60ING]

So with being state-side, I thought I'd be able to help out with the swap. I've made it over there twice I had a lot more going on than I had anticipated on the way home. But, we were able to discuss some issues that have been giving him problems, and I'm hoping you guys have some insight:

1) With the 02J, we noticed there were differences in the box/shifter cables (I guess NB and then Golf/Jetta). Now, are there differences in the master cylinder and vehicle speed sensor as well? We're trying to figure out which VSS/MC to use, or if there will be a difference.

Just use the stock Corrado Clutch MC and Slave Cylinder. Use the any VSS, as far as I know they are all the same. for the shifter the early 1999.5 setup is the same as a mk3 TDI/VR6 and SLC. The later MK4s I really don't know much about but I know they can be swapped and the later style is more desirable. There is a huge thread with details in the corrado forum for swapping to the 02J shifter

2) For the TDI gurus, the EGR delete; possible or recommended with the Kerma PD150 kit?
For now do your self the favor of deleting the EGR with some block off plates from www.idparts.com I ran bloacked off for a long time with no issues.

3) Can anyone with a late ALH (such as this one) take a picture (or have pictures) of the routing of the coolant hoses? There's slight confusion on the thermostat outlet hose/overflow.
I'm no help on this, Alls I know is that it will seem like spaghetti when its done.

4) We have a Mk3 VR K-frame (or at least it's what I thought it was) with Mk3 VR motor/trans mounts. The passenger side seems to sit extremely high; the EGR valve (on top of the intake) will not clear the hood. Are we missing something? It just doesn't seem like it's sitting correctly, but we have no TDI or decent pictures to compare.
The DS will sit a little higher than an SLC's from what I've read. If you have the VR mounts in there you can always cut the rubber

5) Reverse light switch, we need one of the square styles, what would that be off of?
Square or rectangle? you can always swap housings or even shifters. get the shifters sorted and then this is easier to deal with.

6) MAP/IAT: I'm missing that part of the intake piping (as well as the sensor itself). Are there any differences between all the ALH MAP/IATs, or are they all the same (the connector I have for it is a 4pin flat)?
there are different BAR rating MAP sensors for the mk4, but you'll need programing that goes with it, the plugs are all the same.

7) The coolant line going to the charge pipe... I plan on running no intercooler (for the time being; once she's running and driving good with no other issues, I'll start doing slight modifications such as an AWIC; once the money flow is more predictable/stable again ). Can anyone give me some input as far as the significance to that coolant line? To our understanding, the engine will not warm up at idle, and this is meant to help that process, no?
I have no idea what you are talking about

I understand the majority of these questions could be answered with research; which is what I'm trying to do. But, life is getting in the way of this project and I'm currently extremely short on time. Any help is appreciated And there are many updated pictures; I will try to get some ASAP. In the meantime, here's some nostalgic ones from one of my cross-country trips with the car

http://img.photobucket.com/albums/v2...2/IMG_0027.jpg

http://img.photobucket.com/albums/v2...2/IMG_0034.jpg

http://img.photobucket.com/albums/v2...2/IMG_0136.jpg

http://img.photobucket.com/albums/v2...2/IMG_0210.jpg

On a side-note, we've decided (after much debate) to keep the Mk3 and sell the Mk1. So if anyone is looking for a rebuilt 1.6D (NA) 5spd Mk1 (literally everything mechanical is new; no joke), send them our way! And the Mk4 is still a POS that continues to break away at our checking account for new parts.

[girdwood]

Just use the stock Corrado Clutch MC and Slave Cylinder. Use the any VSS, as far as I know they are all the same. for the shifter the early 1999.5 setup is the same as a mk3 TDI/VR6 and SLC. The later MK4s I really don't know much about but I know they can be swapped and the later style is more desirable. There is a huge thread with details in the corrado forum for swapping to the 02J shifter
I don't know where the miscommunication was, but I messed that one up... that wasn't what my friend needed to know, but he already figured it out haha

For now do your self the favor of deleting the EGR with some block off plates from www.idparts.com I ran bloacked off for a long time with no issues.
I have to call Kerma tomorrow and see if they need to re-program the ECU after doing that.

I'm no help on this, Alls I know is that it will seem like spaghetti when its done.
We found a printout from All-Data; should be enough to go off of

The DS will sit a little higher than an SLC's from what I've read. If you have the VR mounts in there you can always cut the rubber
I don't really want to jeopardize the integrity of the mounts themselves, we already had to hack away at the rear bracket to make it fit with the turbo.

Square or rectangle? you can always swap housings or even shifters. get the shifters sorted and then this is easier to deal with.
IIRC, 2pin square... I have to dig through the pictures and verify

there are different BAR rating MAP sensors for the mk4, but you'll need programing that goes with it, the plugs are all the same.
when I talk to Kerma tomorrow, I'm going to see if which one they programmed my ECU for... I remember having this discussion with them, but it's been so long

I have no idea what you are talking about
It was the EGR cooler that I was referring to... but, it's being deleted anyways.

[girdwood]

So when I bought the car, it was a wiring nightmare already... haggard 'fix' jobs, aftermarket wires everywhere (alarm, stereo, etc), splices, power-stealers, etc. Since we were basically meshing 2 harnesses together, my buddy was kind enough to fix everything else while he was in there. It's still a work in progress with the wiring, but he's done a LOT already.

Current interior:




Wires cut from the 'original' Corrado harness




I don't think this is supposed to be exposed... (spoiler relay)


The Mk4 Harness that's being adapted to the Corrado's


Clearance for the AC compresser (had to grind/re-weld the subframe slightly to allow flex from the engine mounts)




Passenger side clearance




This is the possible issue right now... it seems to be sitting extremely high


And the passenger side seems to be elevated




This is the go-pedal connector (round) and the harness for it (rectangle). We need to figure out which way we want to go with this..


Actual go-pedal (I need to verify what it's out of so we can wire it properly)


Bought these for my old 1.8BT Syncro B3 wagon, but sold it before I had a chance to install them. So why not put them on here?


New subframe/steering rack (my old one was destroyed, and the housing was somehow cracked.. pictures later)




This is the VSS connector that we have on the harness (bottom right), and the VSS we have installed (top left). We need to figure out what would be the best route to go to make this work (would like to know if we can keep the harness wiring and just buy the correct VSS for it, but what is it?)

[girdwood]

Do I have options on intake manifold setups? It would make life a hell of a lot easier if the airbox was on the driver's side instead of the passenger... ideas?

[girdwood]

Do I have options on intake manifold setups? It would make life a hell of a lot easier if the airbox was on the driver's side instead of the passenger... ideas?

I'm not finding much in the ways of this, does anyone have any insight?

[MrDave]

intake manifold doesn't have much to do with your airbox placement,
it has more to do with your intercooler placement and pipe routing.

If you want your airbox on the driver's side. You need to consider the pipework from the airbox to the turbo.

On the mk4 TDI, the airbox is on the driver's side, but the turbo intake is on the passenger side. An upgrade on the mk4 is the "old man intake". Kerma has one available.

http://www.kermatdi.com/servlet/the-...Intake,/Detail

On the mk3 TDI, the airbox is on the passenger side.

Looking at stock intakes: the mk3 points to the driver's side, but the EGR is integral.
The mk4 points to the passenger side, the egr can be unbolted and removed.
European intakes offer different options, I believe. Take a look at TDIclub.

-Dave

[girdwood]

intake manifold doesn't have much to do with your airbox placement,
it has more to do with your intercooler placement and pipe routing.

If you want your airbox on the driver's side. You need to consider the pipework from the airbox to the turbo.

On the mk4 TDI, the airbox is on the driver's side, but the turbo intake is on the passenger side. An upgrade on the mk4 is the "old man intake". Kerma has one available.
http://www.kermatdi.com/servlet/the-...Intake,/Detail

On the mk3 TDI, the airbox is on the passenger side.

Looking at stock intakes: the mk3 points to the driver's side, but the EGR is integral.
The mk4 points to the passenger side, the egr can be unbolted and removed.
European intakes offer different options, I believe. Take a look at TDIclub.

-Dave

Thanks, I'll have to take a look at TDIclub and see if there's any other options.

It took me a minute to find out which 'go-pedal' I bought, but it's a B4 pedal. I have the harness/ECU from the Mk4 ALH and have the pinout for that side of the connector, but not the side from the pedal/sensor itself (for some reason, having a hard time finding that). Still working on cleaning up the old BS harness before we completely integrate them, and we want the car running with pedal working before we start putting stuff back together. I'm still saving monies to get a few more odds and ends, which is the cause of the slight pause now.

Right now, the parts list (that I can remember) is:
custom PS lines
custom AC lines
fluids/filters
MAP/AIT
intake (more than likely that Kerma piece)
custom downpipe
EGR delete kit
I know I'm forgetting stuff...

[girdwood]

Does anyone know if the Corrado sunroof pieces are compatible with other cars (such as B3/B4)? I need the piece that has the nipples to connect to the drains at the rear, but want to know if I can pull one off of another car at the yards up here.

[G60ING]

The B3/b4 sunroof will bolt right in as a whole assembly into the corrado, there are dozens of threads on this. Some of the parts swap without problems and I think the drain parts will.

For intake manifolds you can't unbolt the EGR valve from a Mk3/B4 TDI but you can get a european B5 PD Passat manifold or you can cut the Mk4 manifold in half and have it flipped.

Here are some tdi intake manifold threads you might find helpful:
http://forums.tdiclub.com/showthread.php?t=260729
http://forums.tdiclub.com/showthread.php?t=299857
http://forums.tdiclub.com/showthread.php?t=248172

[G60ING]

It took me a minute to find out which 'go-pedal' I bought, but it's a B4 pedal. I have the harness/ECU from the Mk4 ALH and have the pinout for that side of the connector, but not the side from the pedal/sensor itself (for some reason, having a hard time finding that). Still working on cleaning up the old BS harness before we completely integrate them, and we want the car running with pedal working before we start putting stuff back together. I'm still saving monies to get a few more odds and ends, which is the cause of the slight pause now.

http://forums.vwvortex.com/showthrea...-pedal-instead

[wed3k]

have you considered the pd110 intake manifold?

its off a euro eurovan? or something bigger than a car.

[G60ING]

have you considered the pd110 intake manifold?

its off a euro eurovan? or something bigger than a car.

... but you can get a european B5 PD Passat manifold...

Here are some tdi intake manifold threads you might find helpful:
http://forums.tdiclub.com/showthread.php?t=260729
http://forums.tdiclub.com/showthread.php?t=299857
http://forums.tdiclub.com/showthread.php?t=248172

its included in the links above. I have one on my car

[G60ING]

here you go:
http://www.ebay.co.uk/itm/Vrvws-VW-P...item20ce28349e

[girdwood]

Thanks, man! Are all TDI manifolds interchangeable then? Seems like I might be able to swap the manifold with one of the others and solve 2 issues with doing that (intake input side and EGR). I haven't had a chance to do anything on the Corrado lately, and we're about to go to Hawaii for a while... no updates in the near future.

[ruiemichelo]

Everything else is just getting banged out and smoothed over

[girdwood]

Yes, for the most part. The rear wiper was shaved, front squirters, antenna, rear emblem, seam welds, etc. And then there's a few goodies from SpoonFedTuning (grille, windshield cowl, plate tub) awaiting paint. The front bumper is a little warped, so that just got sanded down and re-painted; I'm going to replace it eventually, I didn't want to waste too much time and materials on the parts that aren't staying. Overall, the car looks great, but it is not being built for show, it's going to be my daily.

[G60ING]

Yes the tdi intake manifolds are inter changeable provided they had the D shaped intake ports. If you want a passenger side inlet then just use a mk4 with a race pipe. If you want a driver side inlet than the uk is the best source.

[ziggydub628]

Is Lars still working on this?