Jim Bowen Corrado VR6 - New engine build

[til2143 0]

Looking good, love speedlines, it must feel like a new car now :)

[CazzaVR 0]

All coming along nicely 8) Speedies look excellent :D

[Jim Bowen 1]

Not had any updates for a while, i got corrado out of the garage over the weekend, i've not used it since about october time.

 

 

It still works, took a few times to start and didn't idle but after a quick spin it was back to how i left it.

 

Got loads to do to it now, will be going back into garage i think :lol:

[Jim Bowen 1]

i also decided to type some sort of spec or just a list of how the car is and what i've done, mainly for my own mind as i'm starting to forget.

 

1995 Volkswagen Corrado 2.9 VR6

Classic Green Pearl

Black Leather Recaro Interior (Electric movement & heated)

 

Modifications

KW Variant 1 coilovers (inox)

288mm Golf front brakes + goodridge hoses

Mk4 Golf rear brakes + goodridge hoses

Powerflex rear beam bushes

BMC Cda air induction kit

Magnex oval cat-back exhaust

Gruvenparts alloy radiator neck

Gruvenparts alloy coolant/crack pipe

Gruvenparts alloy aux pump bracket

Samco coolant hoses

Mk2 Audi TT wiper arms & blades (2x drivers side)

FK Debadged front grill

Smoked headlight protectors

Clear side repeaters

 

 

 

 

Replaced parts

Original Speedline wheels professionally refurbished

Top mounts complete set

Wheel bearings complete set

Wishbones + bushes

Balljoints

ARB Droplinks

Track rods & ends

Coilpack & leads

Radiator

Thermostat housing

Clutch kit

Aux water pump

Handbrake cables

Brake lines

Bonnet release cable

Sub frame bolts

Leather Gear knob

Foot pedal rubbers

Roof aerial & rubber seals

 

 

Have also got a chore list nearly as long of things i need to sort out this year, have noticed the start of rust on the front wings and tailgate (i reckon tailgate has been resprayed in the past)

 

Have decided i should really check out the timing chains and tensioners as i don't know what state they are in after 194,000miles, the steering rack is to be replaced and think i may attempt the fixed column polo one that i've heard of on here.

 

so i think front end will be coming to bits, subframe off, engine out if it has to? going to clean the bay up and reassemble, i think i have most of the bits already so most of it should just be labour, apart from any painting i may have to pay out for.

[Jim Bowen 1]

Well corrado is back in the garage now, taking it apart, finding any rust to fix and having a general tidy up now. Had the car for 5yrs and replaced most of the stuff that breaks so hopefully this won't be too expensive.

 

 

Think i may as well remove the aircon, never used it and don't think i'm going to start using it.

 

Found the rust in front wheel archs, everywhere else seems solid and these bits aren't too bad, can get the welding done for nothing.

 

 

am hoping i can fix the wings and not need to replace them

[Jim Bowen 1]

Going to start updating this, now i have most of the parts i need to build it back up again. Hoping to get it done in the next few months

 

Engine beam in place

 

Subframe off

 

Cleaned up the subframe, got most of the rust off with Deox gel and the dremel.

 

 

Painting with this stuff for now, as a primer

 

 

First coat done, need to wait till its dry to flip over and paint the other side

Edited April 30, 2012 by Jim Bowen

[Jim Bowen 1]

Steering rack is now cleaned up, fixed all the track rod issues and measured it all out so rack is central and the LHS track rod is to factory length.

 

Put it back on subframe, i used jubliee clips on the smaller of the two boot clips, as its easier to be able to undo them and spin the boot straight if needed

 

Cleaned up the ARB and given it some paint

 

Also decided to scrape off aload of underseal as was only way to check the sills properly, took ages

Luckily all the bits i'm doing is underneath and out of eye line when stood up

 

Holey rusted metal batman!

 

Will let photos do the talking as pc i'm on is so slow i'm about to smash it up

 

---------- Post added at 11:12 AM ---------- Previous post was at 11:04 AM ----------

 

Glad i did this rust when i did, as most of it was unnoticable. Was only a 5p sized hole that made me look.

 

Sills cleaned off, rather save these the most

 

Missing some photos, pc being annoying, so here are the last, i will update at some point.

I've ground rust with a grinder.

Then used the 3 stage POR15 rust treatment, grey paint, will do another coat of POR15 in black, have sealed the seams with joint sealer, then got schutz to reapply once i can borrow a compressor. Also got new cavity waxes to apply on the inside of sill.

 

Welding repair isn't the most pretty, but i'm just want it solid and rust free so i can drive it everyday and use it properly

[DriverVR6 11]

Nice work. Really good to see someone doing the work themselves, and learning and picking up new skills along the way.

[Jim Bowen 1]

Cheers, feel like i'm getting somewhere now.

 

Got rid of any rust on inner wings and sprayed some wax protection on them

 

Subframe is now inside, just waiting for engine mount from Jay then i can refit it to car

 

Took the seats out while i work on interior, got all the aircon removed now, fixed the electric movement of seats, and fixed headlight loom in dash (again)

 

Started to sort out the slam panel, i think this rust is why the bonnet realease cable fails, the metal tab that cable pushes against has rusted and moves very slightly, meaning i keep having to adjust my cable ends

 

Also, does anyone know if its important which way this X goes on the gearbox mount?

 

Can't see what it means

[Jim Bowen 1]

Got the front cross member and rad support off and dropped them at the powder coaters to be plascoated, will get pics when i get them back.

 

Did the inner wing bits that aren't covered in the VW stonechip stuff, painted them with POR15

 

Then decided to use the black Schutz stuff to go over that and also over the original stone chip in arches, Should stop any moisture and future rust.

 

How car is at the moment

 

In other news, i got the subframe back on and connected the steering up.

 

Fitted the new Outer CV joint

 

More stuff waiting to go on

 

Another question (if anyone actually reads here :lol: )

 

^^^For the sump do i need the gasket and sealant or just the gasket?

[CazzaVR 0]

Wow! Amazing work mate- will be totally worth the effort when it's all back together 8)

 

Don't think it matters which way round the gb mount goes.

 

I would use a thin bead of sealant with the gasket.

[Overmind 10]

Looking good :). I second the above by the way, I think the mounts at symmetrical and I would use a small bead of sealant.

[Jim Bowen 1]

Cheers, going to use a smidge of sealant i think..

 

put my shocks back in

 

Took the hubs to garage to have new wheel bearings pressed in, then i can fit them and maybe get car on its wheels again.

 

Stripping bits from here to get ready for timing chains

[VAG-hag 0]

fancy doing another?? :lol: looking good mate.... in it for the long run then this stuff needs doing! Our lass says up yours for giving me ideas!

[Jim Bowen 1]

Its not that hard really, just putting in the hours and remembering where everything goes. I would take it apart again if i need to, i seem to have a lot of patience and time.

 

Mainly hoping to stop any rust and sort out my steering (which i think i have fixed now), Its not going to be a concourse show car, i plan to use it through the winter etc

[job705 10]

lovely car fella hope you enjoying it

[Jim Bowen 1]

Just picked up my hubs, had to get a garage to press the bearings in for me.

 

 

Can put them on now and complete some of the suspension/steeering :! Just the brakes then i can put wheels back on.

 

Although might leave one side as gearbox is coming off to do timing chains

[Jim Bowen 1]

Slung them on the car

 

 

Cleaned up engine some more and stripped **** off ready to do timing chains, hopefully this weekend

[Jim Bowen 1]

Got the timing chains and associated bits done yesterday. All went really well using the guide from here and some help from a mate.

 

Some pics, didn't get them for every step as was busy cutting my hands on the gearbox

 

This is where the gearbox was

 

Took clutch and flywheel off

 

BEFORE:

 

AFTER:

 

Has the mk4 upgraded top tensioner now. Will get pics of what came off, bits were snapped in half and the top tensioner worn right the way through and starting cutting into the metal part :! was shocking

[Jim Bowen 1]

Got bits back from powder coaters

 

Fitted that and the cross member, Those bushes are tough!

 

 

Did a few other bits today, like new header tank, new PAS bottle, new fuel lines

 

 

Got quite a bit done today, but its hard to see what i have done tbh

[VW_OwneR_85 1]

good blady job sir!, with the box off the engine ,how hard were the chains and guides to replace?

[Jim Bowen 1]

Pretty easy really, i did watch my mate did it and was telling him what to do (once he got stuck in he wouldn't stop), i reckon i could of done it. The hardest part was getting the gearbox off. Really awkward. Still got the deep cut in my hand :lol:

[Jim Bowen 1]

Done some more bits, painted the slam panel up and trail fitted with the grill, mainly because it looked cool

 

 

VR6 means the engine it has

 

Aux water pump/thermostat and some samcos back on

 

Throttle body all connected up

 

Suspension/steering back on both sides now.

 

Not very intersting, but its a bit more progress, hurt my hand so couldn't do much last week

[Jim Bowen 1]

What is going on with my thread, i can't view the last past and a new reply by me seems to keep it on page 3?

 

This post is a bit of a test really, to see what happens

[Goldie 2]

It worked and those hubs look nice.. Good progress..