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    Thread: The Stormtrooper vr6 build thread

    1. Member bulfrog3232's Avatar
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      03-15-2012 12:42 AM #1
      I have had my 91 16v GLI for about a year now and it ran fantastic until last weekend. i was on my way to pick up some parts for a vr6 swap into my corrado, and in the middle of nowhere north dakota (not hard to guess why) my front motor mount broke and my engine fell forward pressing all the weight onto the oil filter and crushing it, soon after seizing my 16v.
      After 4 hours of waiting for a tow truck driver to pick me up i decided the jetta would now be the suitable companion for the new vr6.
      on to info:
      the car is an alpine white 1991 GLI with 195000 on the body and engine
      the vr6 is a fresh rebuild that came with both subframes rack and pinion ecu wiring harness and... an auto transmission
      I'm driving 9 hours this weekend to pick up an 02A 5 speed and some corrado parts and ill try to have this running as soon as i can.
      I Will take all the advice i can get
      on to the pics








    2. Senior Member cyclops594's Avatar
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      03-15-2012 12:55 AM #2
      Right on man. Sounds like ya have a solid game plan. Good luck.
      Tuned in...

    3. Member bulfrog3232's Avatar
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      03-15-2012 10:01 PM #3
      Little update today, I removed the engine wiring harness that goes to the back of the fuse box and cleaned up the engine bay. I plan on doing a semi shaved bay and can't decide wether to paint the nay black or white. On to the pics




      Do the vr and 16v share the same fuse box? And does anyone know a diagram showing what vr6 connectors go where on the fuse box? mine were not labeled.
      Thanks

    4. Junior Member
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      03-15-2012 11:56 PM #4
      Diggin the storm trooper theme!
      an older fellow once told me "boy i remember the days when i had my car, my wife, and my money... i sure do miss my car and my money!!"

    5. Geriatric Member steveo27's Avatar
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      03-16-2012 09:07 AM #5
      It is all plug and play in a CE2 car, which yours is.

      The 3 main connector are F, G1, & G2. Then w/o1 for the VSS & injector power from z1 or the 30/30b jump.
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    6. Member bulfrog3232's Avatar
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      03-16-2012 12:35 PM #6
      What cleaners do you guys use to clean your engine bays?
      I think I'm going to sand and prime the bay today.

    7. Member MOTA BOY's Avatar
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      03-16-2012 01:03 PM #7
      It's gonna be great!

    8. Member shwak23's Avatar
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      03-16-2012 06:36 PM #8
      Purple Power.... aircraft stripper....

      Sent from my DROID X2
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    9. Member bulfrog3232's Avatar
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      03-16-2012 11:32 PM #9
      not too much to update today. cleaned the bay some more with the purple stuff, routed the vr ecu, (still need to figure out the main harness into the fusebox) removed old shifter box and f*** up the exhaust shrouding in the process
      going to minnesota to buy my 5 speed transmission tommorrow and a hood for my corrado

    10. Member slakr7555's Avatar
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      03-17-2012 01:26 AM #10
      in

    11. Member bulfrog3232's Avatar
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      03-19-2012 11:52 PM #11
      Got my o2a transmission and now I'm just waiting on the other parts being freighted hopefully I can start to do real work on Wednesday.
      In the mean time I did some cleaning and resprayed the intake manifold and preped the tranny for paint. And for parts for relocating the battery.
      On to pics








      Does anyone know what the difference is between automatic and 5speed throttle bodies?
      Can't wait for a big update by the end of the week

    12. Member remmyGLI's Avatar
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      03-20-2012 12:02 AM #12
      Nice work
      DCI-EAST

    13. Member bulfrog3232's Avatar
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      03-20-2012 12:21 AM #13
      Also just ordered a tectonics tuning 2.5 inch exhaust with 2 resonators and a borla muffler. Should sound mean.

    14. Member bulfrog3232's Avatar
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      03-22-2012 10:14 PM #14
      My progress


    15. Member bulfrog3232's Avatar
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      03-25-2012 12:04 AM #16
      Tonight i Got the o2a shifter in, the tierods, ball joints, steering rack in.
      The only thing I have left to do swap is the pedal cluster from a mk3 which looks like a huge PITA. The clutch assembly which also looks like a pain, And remove a stuck bolt on the flywheel so I can put the engine and tranny together. And then finish up some wiring. As always any advice is appreciated
      An pic of progress

    16. Member bulfrog3232's Avatar
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      03-30-2012 05:36 PM #17
      Got the engine in, just having a tough time getting the new Sachs clutch in, does anybody know how to figure out the correct fitting for the three clutch pieces?
      On to pics





    17. Member boostedbastid's Avatar
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      few here, few there, big whoop wanna fight about it?
      03-30-2012 06:58 PM #18
      Do metal crack pipe and more cleaning/painting of your accessories while everything is still open. You will be much happier in the end.
      DubSaints Alpine White supremacist

    18. Member bulfrog3232's Avatar
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      04-01-2012 02:03 AM #19
      Just need to finish wiring, get the pedal cluster in and some other final touches, should have it running in a week and tuned sometime within the month
      can't wait to drive this!
      On to pics






      And a pic of my daily

    19. 04-01-2012 05:08 AM #20
      It's gonna be great!

    20. Member Road Boss's Avatar
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      04-01-2012 12:21 PM #21
      Nice work!

    21. Member bulfrog3232's Avatar
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      04-09-2012 12:23 AM #22
      Small update, got the pedal cluster in, the wiring is nearly complete, and i have have the old exhaust almost out. i just ordered a corrado g60 radiator, the ecm relay 109, and the brake booster bracket. should have all my parts by the end of the week.
      will post pics tomorrow of progress.
      but in the meantime a buddy of mine came by and did a quick few shots and a teaser video




      and a teaser video
      http://www.facebook.com/photo.php?v=...type=2&theater

    22. Member MOTA BOY's Avatar
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      04-09-2012 04:15 AM #23
      Great!

    23. Member bulfrog3232's Avatar
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      04-19-2012 12:16 AM #24
      Finally got time to take some pics and I have run into a few problems.
      I got my new Corrado g60 radiator and it's a very tight fit without running fans so what do you guys do to have a little more room. Also there is a different flange on the top of the radiator and I don't know what I need to fit a hose onto it.
      The wiring is nearly complete I think, I have wired up the main harness connectors and I just have a few random wires to connect. I have the 109 relay and put the 15 amp fuse in the starter bypass but I still cannot get the car to start, the starter spins but there doesn't seem to be any fuel or spark.
      I got the brake booster bracket off eBay and started to drill the hole on the right for the stud to go through the firewall when my drill battery died and so did my motivation.
      I have also started to remove the old exhaust and prepared the new Techtonics tuning 2.5 cat back
      Hopefully I can get the car to run soon because my g60 Corrado is on the verge of grenading.
      On to pics










    24. Member sleepin gti's Avatar
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      04-19-2012 03:03 AM #25
      plan on doin this when the vrt is to the point im comfortable with leaving it at for a while. by then the mk2 should be about ready for a swap lol. keep up the good work

    25. Member db3ck's Avatar
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      04-19-2012 09:26 AM #26
      very nice thread looks like its comin along great
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      04-19-2012 03:51 PM #27
      I am your FATHAH!!!!!
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      04-19-2012 09:09 PM #28
      Buy a set.of push style fans for your radiator. Summit has them
      VW's the older the better
      http://www.4everkustoms.com/ <=THE BEST
      BUY MY PARTS MKII MOSTLY
      http://forums.vwvortex.com/showthrea...7#post82154097

    28. Member bulfrog3232's Avatar
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      04-23-2012 07:53 PM #29
      I have found a way to make the mk2 fans work with the Corrado radiator so for now thats what I'm going to use.
      But I do have a problem with my brake booster, I installed the bracket for the master cylinder and the bracket uses the holes into the firewall that the. Booster used, is there another piece that I need other then this one

    29. Member bulfrog3232's Avatar
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      04-28-2012 01:59 AM #30
      I was working on my car tonight and it is so close to starting, I just need power to the coilpack, what do I need to do to get the spark plugs to spark?

    30. Member bulfrog3232's Avatar
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      04-30-2012 11:16 AM #31
      I have spark now! But I'm still not getting fuel, the car will start for a second with carb and choke cleaner, and the fuel pump does pressurize and my lines are correct I don't believe the injectors are priming.
      What do I have to do to get the injectors to prime and get my car running finally?! Is it the 30 to 30b wire because I have not done that. And what do I need to do?
      Thanks again vortex






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    31. Member bulfrog3232's Avatar
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      04-30-2012 05:00 PM #32
      I Know what i need to do, but i dont at the same time. the post says if i have a OBD1 Passat wiring harness i need to
      you will see the red and yellow wire in this pic this will power up your injectors ETC just cut off the end of it and put a connector so it will fit one of the Y slots.
      But i dont know what he means by the y slots? Does he mean on the back of the fusebox at y1-4?
      anybody able to help me out real quick?
      Thanks!

    32. Member bulfrog3232's Avatar
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      05-05-2012 07:33 AM #33
      Found out I have obd2 not obd1 car still doesn't start because of fueling issues, gotta check for injector pulse tomorrow.
      And some wiring shots... Really don't like wiring haha
      Last edited by bulfrog3232; 05-05-2012 at 07:36 AM.

    33. Member bulfrog3232's Avatar
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      05-05-2012 07:52 AM #34
      http://i337.photobucket.com/albums/n...2/15647747.mp4
      With just a dab of carb and choke cleaner.
      But once it gets burnt up the car just cranks because the injectors aren't spraying fuel

    34. Senior Member christofambrosch's Avatar
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      05-05-2012 12:13 PM #35
      Quote Originally Posted by bulfrog3232 View Post
      And some wiring shots... Really don't like wiring haha
      Who does? Haha.

      Looking good so far. Keep up the good work.

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