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    Thread: The Stormtrooper vr6 MK2 build thread

    1. Member bulfrog3232's Avatar
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      03-25-2012 04:32 PM #1
      I have had my 91 16v GLI for about a year now and it ran fantastic until last month. 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 and progress since then












      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









      Tonight i Got the o2a shifter in, the tierods, ball joints, steering rack in.
      Does anyone know what the difference is between automatic and 5speed throttle bodies?
      The only thing I have left to do swap is the pedal cluster from a mk3 which looks like a huge PITA. Does anyone know a diagram showing what vr6 connectors go where on the fuse box? mine were not labeled.
      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.
      As always any advice is appreciated
      An pic of progress

    2. Member bulfrog3232's Avatar
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      03-30-2012 04:38 PM #2
      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





    3. Member Shaniqua's Avatar
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      03-30-2012 08:05 PM #3
      just snoopin around, thought id say nice work

    4. 03-30-2012 11:34 PM #4
      did you hammer in the frame rail yet? You should be able to tell where with the engine in there.

      Its a lot easier to get the engine in with the trans on it already.

      For the pedal cluster its a ton easier to use B3/B4/Corrado pedals as they bolt right up, the mk3 ones won't and are very hard to make work. Also a non ABS B3 or any B4 will have the booster/clutch bracket you need.

      To use a mk3 or B3/4 VR6 radiator a B3 16v 5 speed rad support fit perfect and hold it straight, not at a weird angle, otherwise if using a corrado radiator the stock mk2 support works.

      for wiring what do you have? the mk3 stuff can be made to fit but i like using passat stuff as you can leave the mk2 headlights and it plugs into the fan harness under the mk2 dash with out having to change it all over. with the passat stuff its 4 connectors and it runs.

    5. Member bulfrog3232's Avatar
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      03-31-2012 02:00 AM #5
      i have not had to hit the frame rail in yet, plan on it tomorrow, i have a corrado vr6 pedal cluter, i dont recall what front subframe i have but i have the b4 passat rad with twin fans, and the 1994 passat wiring harness, the car was an automatic when i bought it do you guys know if there is anything i have to change for the 5 speed swap?
      thanks for the help

    6. Member bulfrog3232's Avatar
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      04-01-2012 01:05 AM #6
      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

    7. Member bulfrog3232's Avatar
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      04-08-2012 11:23 PM #7
      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

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      04-09-2012 03:32 PM #8
      where are you as far as wiring? youshould just have to plug in g1 and g2..and for reference, it is labeled on your fuse box..get in there with a good LED light and look..but the labels are there buddy..but g1 and g2(both clear 12pin connectors) are what the engine needs to runs mostly

    9. Member bulfrog3232's Avatar
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      04-10-2012 02:41 AM #9
      I have the main harness connectors in and all I have left are a few random wires. I ran the 15 amp fuse through the starter bypass alarm wires and I just bought relay 109 for the ecu. I'll post pics tomorrow.

    10. Member bulfrog3232's Avatar
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      04-18-2012 11:16 PM #10
      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










    11. Member volkswagenpaul's Avatar
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      04-19-2012 09:48 AM #11
      Are you OBD1 or 2, the 109 relay is for OBD1 only. I had the same problem with fuel and spark and discovered that the crank sensor and knock sensor plugs were switched. Hope that helps.

    12. Member bulfrog3232's Avatar
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      04-19-2012 05:13 PM #12
      I believe it's obd1 with a coilpack. The engine is from a 94 passat and I'll have to check the wires today thanks

    13. Member bulfrog3232's Avatar
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      04-23-2012 06:53 PM #13
      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

    14. Member Minty-MkII's Avatar
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      04-25-2012 04:18 PM #14
      Did this swap on my 1.8t. That bracket sort of replaces the bracket on the back of the mk2 brake booster then the studs will go all the way through the firewall like the stock setup IIRC. So just remove the backet on the brake booster and see if you can get it to work.
      "As men, we know NOTHING turns a girl on more then a well executed handbrake turn...Peacocks have their feathers, Men have the handbrake"
      Check out the 8v to 20v Conversion Story

    15. Member bulfrog3232's Avatar
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      04-28-2012 12:57 AM #15
      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 get the power?


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    16. Member AJmustDIE's Avatar
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      04-30-2012 01:37 AM #16
      Quote Originally Posted by root beer View Post
      It's Timmy with mmmmMojo, i have returned
      8VALVETURBO - RIP White Jetta

    17. Member bulfrog3232's Avatar
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      04-30-2012 10:16 AM #17
      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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    18. Member volkswagenpaul's Avatar
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      04-30-2012 03:20 PM #18
      This helped me a lot when I was doing my wiring.
      http://mk2vr6.com/board/viewtopic.php?f=12&t=7831

    19. Member bulfrog3232's Avatar
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      04-30-2012 03:58 PM #19
      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!
      Last edited by bulfrog3232; 04-30-2012 at 04:01 PM.

    20. Member volkswagenpaul's Avatar
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      04-30-2012 05:00 PM #20
      Yes, the "Y" slots are on the back of the fusebox. You need to do the 30-30b jumper also.

      Here is a pic of mine for reference, but I'm OBD2 so my injector signal is at Z1.

      The "Y" slots are in the front of the pic.

    21. Member bulfrog3232's Avatar
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      04-30-2012 07:02 PM #21
      this is a rookie question but what is the 30-30b injector splice? i cant find those pins on the fusebox and everywhere i search i just see the pic i posted from mk2vr6.com
      thanks again

    22. Member volkswagenpaul's Avatar
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      04-30-2012 07:30 PM #22
      You can see the 30-30b jumper in the back right of my pic, next to the yellow plug. You need to connect those 2 terminals for your fuel pump to get power. I used a factory jumper that I had, but you can make one if you don't have one.

      This is another helpful site
      http://www.a2resource.com/electrical/CE2.html
      Last edited by volkswagenpaul; 04-30-2012 at 07:33 PM.

    23. Member bulfrog3232's Avatar
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      05-02-2012 10:08 PM #23
      is there any reason i wouldn't have the red/yellow injector wire that splices into the Y's because it was an automatic transmission passat before the swap? I have spent the last 45 minutes looking through my wiring loom for the red/yellow wire and cant find it, but i found a red/blue wire with the correct connector for z1 so i might have OBD2
      ill post pics in a minute but what do i need to do to figure this out!

    24. Member bulfrog3232's Avatar
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      05-03-2012 12:08 AM #24

    25. Member volkswagenpaul's Avatar
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      05-03-2012 09:02 AM #25
      I'm think your OBD2 also, you have 2 O2 sensor plugs and I'm pretty sure OBD1 only uses 1. I would plug in the yellow plug and take the 109 relay out and see what happens. If you don't want to do that, check the pinout on A2Resource and look for continuity between the yellow plug and the corresponding pinout.
      Last edited by volkswagenpaul; 05-03-2012 at 09:21 AM.

    26. Member bulfrog3232's Avatar
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      05-03-2012 12:29 PM #26
      swapped the lines and pulled the relay, no dice.
      going to get a noid tester tomorrow and checking pulse at injectors and checking the pinouts.
      hope i dont have a bad ecu
      thanks for all the help vwpaul!

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      05-03-2012 03:39 PM #27
      obd2 does not have single red connector with red/yellow wire. make sure Z1 is connected. make sure the 30-30b connector is in or nothing will happen. hook up OBD port to see what is going on. Best bet is to take pics of wires in more detail as to what is not connected instead of a big blob of wire and maybe people can help you.

    28. Member bulfrog3232's Avatar
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      05-03-2012 09:32 PM #28
      I have already done the 30 30b jump and put z1 in.
      Tomorrow I'll put up a well written post with lots of pics, And check for injector pulse.


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    29. Member bulfrog3232's Avatar
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      05-05-2012 06:25 AM #29

      And I started to button up the rest of the front end

    30. Member bulfrog3232's Avatar
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      05-05-2012 06:53 AM #30
      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

    31. Member volkswagenpaul's Avatar
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      05-05-2012 08:00 PM #31
      Remove your fuel pump relay and jumper it to make sure it's working, and verify that you have the fuel lines hooked up the right way.

    32. Member bulfrog3232's Avatar
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      05-10-2012 01:01 PM #32
      I swapped fuel pump relays with my running Corrado and did the injector pulse test, both at the injector and ecu pin number 2 I got nothing.
      Is the next step a new ecu?

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      05-10-2012 02:28 PM #33
      does the throttle adapt with the key on? does the CEL come on on the cluster? have you tried scanning the OBD port?

    34. Member volkswagenpaul's Avatar
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      05-10-2012 03:14 PM #34
      Check fuses 9 & 15. Check for power at ecu pin 54 and pin 23. 23 should have power with the key on and 54 should have power all the time. Make sure the big plug on the side of the engine is making good contact, unplug it, check all the pins and make sure nothing is bent or pushed in.

    35. Member bulfrog3232's Avatar
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      05-10-2012 03:26 PM #35
      Fuses are good pin 23 has power when ignition is on and pin 54 never has power to it

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