Black G60 Complete Recondition Project!

[Laggo 10]

So me and my mates invested into this tidy 1992 corrado G60 in gray on the idea of reconditioning it for shows and then sell on for profit, so we payed £1,400 for the motor it has 140k on the clock tones of paper work all old MOT's from the word go, also loads of receipts for services and general up keep, the car body work wise in outstanding no signs of rust top to bottom, no dings or scratches could not find a better example.

 

The car has recently had the supercharge serviced by jabba to stage 4 and a number of bits fitted witch I will mention later on in the build. We don't plan to change much just improve BHP, drivability, recondition all components from engine to axles, and we are re-trimming the whole interior for a more modern feel.

 

Here's some photos of the day we bought and cleaned her.

 

 

 

 

 

 

 

Well there you go, so the first weekend we had it we took her for a spin had a quick joy ride before we started the work loved every second of it haha.

 

We cracked on with taking the engine and front subframe out the same weekend and I must say I've never removed such a simple engine haha, we had the lot out in 4hourse. We found a few bolts missing in vital areas witch was a concern and a few vacuumed pipes and breather pipes just layer there not attached to anything so will be posting photos to see if any of you guys can assist, almost all seals need replacing news rear main oil seal, coolant seals ect

 

Anyway onto the photos.

 

 

 

 

Sorry for the poor photos ill have more at the weekend :)

 

But just a quick one fellas, do any of you know where the horn is located as we can't find it and the horn does not work so were thinking it was removed for some weird reason????

 

Thanks for reading!

[GrahamU 6]

Looks like a good one

 

The horn would of been behind the grill, one horn bolted onto either side of the center section

 

Not the best pic, but you can see them in my pic

 

[Laggo 10]

Looks like a good one

 

The horn would of been behind the grill, one horn bolted onto either side of the center section

 

Not the best pic, but you can see them in my pic

 

 

I can indeed cheers mate your a star.

[Hofmiester 10]

Good buy for £1400! looks good.

[Laggo 10]

Yeah thanks man, we're chuffed to bits with it, it was traded in at our work they was going to block it as we're a main dealer but me and my mate decide to invest ;)

[Laggo 10]

Just a quick one people, we're looking to invest into a full system exhaust we're working on a budget here so reasonably priced I've looked everywhere and can't find many, we like noise so what would you recommend for a full system and what manifold would suit best?

 

Cheers guys!

[northG60 0]

I would probably go for a jetex 2 or 3 box system (if it were my money) it'll set you back like £350 but i read allot of good things about the fit for the G60 and its also got a large 2.5" bore which is pretty meaty (most are only 2.25" or 2" )and will give a good noise.

 

http://www.venommotorsport.com/product_details.php?id=2116&manufacturer=Jetex&category=Exhaust

 

otherwise i would say find a custom exhaust place and get some quotes in but its gonna hit the £300 mark

 

also try to source a Decat pipe if it hasn't already got one

 

manifolds are pretty big money on G60's(£500 mark spanking new) as there are loads designed for left hand drives which will burn through your steering rack you need to be careful which you buy

 

might be worth getting your original manifold ported out with matching porting on the block ? again pretty expensive

 

you could easily spend well over £1000 on a NEW zorst, decat, manifold

 

would sound sweet though 8)

Edited August 28, 2013 by northG60

[VR6Pete 0]

Keep an eye on the thread in group but feelers

 

Currently working with dub power to produce a OE looking exhaust :)

[JMC 0]

Take it from someone who has tried different exhausts on a G60, 2.5" is too big for standard or even slightly uprated tuning. Unless you're planning 250+ bhp or turboing, stick with a 2.25", it'll be meaty enough. If you go for a 4 branch make sure it is a real rhd one not a lhd as mentioned above. Gwerks used to do them, but I'm not sure who else does these days, apart from as a custom job. Not sure on the legallity of decats on a K reg, seem to remember reading somewhere about if a car came with a cat and is registered after 92 its supposed to have one for the MOT (of course a friendly MOTer can help there).

 

Nice looking car btw Laggo - glad to see one getting rescued and not being scrapped. Especially like the wheels. Hmmm black wheels on a dark car :-)

[Laggo 10]

Thanks for the advise guys, the car is already fitted with supersprint cat back and a milltek sports cat but its so quite as I'm use to my civic type r with a full system lol, we just won't a nice roar to it, so would you think just get a d-cat pipe and 4 branch would improve the noise level enough? And MOT's won't be an issue.

[JMC 0]

A 4 branch and a decat will make a difference to the sound over the standard. I found with mine there is more of a pulsing to the engine note with a 4 branch. G60's tend not to roar though - they're very different beasts to Type Rs. G60's tend to howl at high revs and full boost. Also I see it's running the standard airbox - take out the snorkel from the inside if it's still there, gives more induction noise from the intake side, and improves airflow. If you want even more induction noise get a decent cone filter (Jabba used to do them, and they come up for sale reasonably often). But whatever you do don't use foam filters.

[Laggo 10]

Really need some advice here setting up the timing for engine before I took it apart and I've followed so many timing methods but no matter what I do nothing lines up I've set the top cam pully to the head but nothing is even close.

 

 

 

[Laggo 10]

Ok quick up date on the progress this weekend, works coming along nicely now we got the timing issue sorted :), engine in bits all wiring looms labeled and slightly removed all bulkhead componats removed and ready for painting all engine bay prepared and masked up ready for painting. Subframe stripped with a number of parts sent off for sandblasting and powder coating. So looking good :) here's a few pics:

 

 

 

 

 

 

 

Here's a cheeky snap of the daily runner civic :)

 

Thanks for reading

[Laggo 10]

Just a quick up date to the progress the bay is all painted up I haven't got any photos as of yet but I will, we've started the rebuild and got a few bits back from power coating look awesome ! Ordered full cam belt kit from VW all new seal mani, inlet, water pump, thermostat you name it all VW. Just got to find a genuine head gasket and rocker gasket as they have been stopped.

 

Here's a small pic of the new bay in Matt black :)

 

 

 

 

 

 

 

 

I had my type r rocker cover done in yellow while I was at it looks mint :)

 

[Laggo 10]

Ok I have Finally got round to doing a progress up date loads done in the past few weeks the car was started for the first time yesterday after the rebuild and she struck strait up a little misfire but only down the dizzy cap not on correctly, just needs a play around,

 

So we have purchased a new raceland 4-2-1 manifold with the jetex de-cat pipe all new samco coolant hose kit in red not yet arrived we have bypassed the RS valve and orderd a pipe kit from Bar Tek that should be here end of this month with the coolant pipes.

 

Here's a list of service parts we've fitted so far:

 

We have put a complete cam belt kit with all belts and idlers, new head gasket & bots, new crank bolt, new clutch kit, new spark plugs, new dizzy cap, replaced all engine seals with new thermostat water pump gasket new throttle body gasket, new o rings on all powersteering pipes new link rods new dust covers on the ball joints and track rods all new ensemble bolts for the front end to bring in a shine, all fluids replaced (completely) with new. New hose clamps through out, new K&N panel filter.

 

We'll more to come hopefully here's some pictures we took over the past 5 weeks.

 

 

Thanks for viewing.

Edited October 7, 2013 by Laggo

[Laggo 10]

Ok so our Bar Tek intake pipe arrived today so I got strait to fitting it it looks grate and really tided things up.

 

 

 

Only fitting issue is I need to extend the boost pressure sensor wore. Nothing major.

[davidwort 0]

Some great work going on there, love to see that sort of work going into a corrado, keep sharing the pics and progress :-D

[Laggo 10]

Thanks man. Yeah looking forward to finishing bit long way to go yet got all the rear end to do the interior ect but she will be a right minter once we're done :)

[JMC 0]

Especially good to see this work going into a G60. Looking forward to seeing how it turns out...

[Laggo 10]

ok really am stuck here now me and my mate have finally finished the engine work on the corrado, we went for the first start up and she struck right up but the idle was all over the place, so we just though ok the ignition timing must be out so, we so we checked it and all was fine, so we towed the car to my work no it wont start what so ever we have checked the timing about 100times the keyway on the crank it fine with new bolt, we have good compression, fuel, air and good spark to all the cylinders. is there anything small we are forgetting we though might of had cam 180degrees out so we span it 180 and made it worse so span it back really need some help here.

 

cheers

[owen g60 10]

Sounds like the hose from the throttle body to the ecu is not connected.

[Laggo 10]

where abouts does the hose connect to the TB? CHEERS

[Laggo 10]

Just fitted a vacuum hose to the ecu and TB still no start

[kerrly 0]

Dam, i'm afraid beyond checking for vacuum leaks I can't offer much assistance, but well done on the work so far, the block/head/components look much better with a fresh coat of paint.

[Laggo 10]

Ok quick update on the situation here, I've been double checking everything again all seemed ok, I removed the rocker cover to check that cam lobes on TDC where rocking witch they where so that takes cam timing out the picture I think, but on a quick check of the oil I found the oil level way over the max line a smelled strongly of fuel could this mean its an overfilling issue or just where we have flooded it on start attempts?