Junkyard Dog - TDI G60 Corrado

[G60'rado 10]

Greeting from Canada!

 

Had an old 91 golf for a number of years, but the body is starting to rot. Plus it will be nice to have something little less of a econobox than a base NA diesel Golf.

 

I acquired a 2000 TDI Jetta that was rolled for cheap. I've been stripping the drivetrain and wiring out of the car. Hope to sell some of the left overs to help recover some of the investment. This started me down the path of looking for a fun replacement to drop the TDI in before the Golf rusts out or dies.

 

I was thinking 2 door coupe; Scirroco or Corrado. I wound up with a 90 Corrado G60 from Edmonton Alberta, that was missing the engine but had a solid body, and an average interior.

 

From my experience in building my first project car (12 years and counting), I learned the value in having a parts car. So I picked up a running 94 VR6 with a rough body, but a good interior, and the "plus" 5 lug suspension.

 

So the plan.. Put the Jetta TDI; the 94 VR6 suspension and interior, and electrical all into the 90 G60.

 

Wish me luck. I have been taking pictures, so I'll post as I go along.

 

Cheers.

Edited August 31, 2015 by G60'rado

[G60'rado 10]

First of the pictures..

 

[ATTACH=CONFIG]77923[/ATTACH]

 

The TDI Jetta and the Corrado at home. Before I started to strip down the Jetta.

 

Engine still in..

[ATTACH=CONFIG]77925[/ATTACH]

 

And out...

[ATTACH=CONFIG]77926[/ATTACH]

 

And car is stripped..

[ATTACH=CONFIG]77924[/ATTACH]

Edited March 4, 2014 by G60'rado

[G60'rado 10]

The 90 is just about stripped.

 

Dash is out, the under dash wiring is removed.

 

I've left the rear wiring in place, just in case it matches up to the 94 CE system, but I'm prepared to swap that out too.

 

Found a nice rats nest of stereo installations, and a crappy 90's alarm system spliced into the harness.. Must of worked great, considering the car was a theft recovery.

 

Next step pull the heater box, and the carpet. Inspect the floors.

 

Then onto phase two.. Clean the garage out, stuff all the parts under the deck, and bring the 94 in, for a much more careful electrical system removal.. and more interior parts to go under the deck..

[GrahamU 6]

sounds like fun, keep the updates coming

[vw bobby 10]

Sounds good, keep us posted

[easypops 8]

Lots of pictures please :)

[G60'rado 10]

The above pictures were from the work this fall. Mostly stripping the Jetta.

 

This weekend, get the 90 into a bare shell.

[ATTACH=CONFIG]77919[/ATTACH] [ATTACH=CONFIG]77920[/ATTACH]

 

And after..

[ATTACH=CONFIG]77921[/ATTACH] [ATTACH=CONFIG]77922[/ATTACH]

 

Joys of this kind of project, if your tired of one part, there's always something completely different to do.

 

I didn't feel like starting into the 94, so I decided to start on my ABS system upgrade. I'm swapping the MKIV Jetta brake system into the 90.

 

First step, modify the brake bracket to take the MKIV vacuum booster.

 

Made the bracket fit the 4 bolts of the booster, fit it up, and discovered it will hit the steering boot/ujoint.

 

Cut the mount section, and tilted the booster up, and re-welded it. A little more cleanup work, and some black paint, and it will look factory.

[G60'rado 10]

Another good weekend.

 

Finished my brake booster mount for the mkiv booster.

 

Also modified my pedal box to take both the mkiv brake, and drive by wire throttle pedal.

 

I'll post some pictures when the paint is dry.

[G60'rado 10]

Been busy the last few weeks working on the 90 and 94.

 

Mostly stripping the 94 down, so I can get 1/2 of my garage back.

 

Got the doors removed, and the dash out.

[ATTACH=CONFIG]78210[/ATTACH]

 

Found a nice surprise in the 94 wiring. The bane of any motoring enthusiast, teenage hack stereo wiring job. No soldered connections, or even crimp on butt splices.. Just wires twisted together and a piece of electrical tape. And not a fuse to be seen..

[ATTACH=CONFIG]78211[/ATTACH][ATTACH=CONFIG]78212[/ATTACH]

 

Which explains why it burnt all the way back to the ignition switch. Looks like the fuse box caught it before it burnt up the harness. I had to replace about 3 wires in the loom, and cut a couple small bad sections out where the insulation was cooked right through. I'm amazed what it didn't set fire to more.

 

Started assembling the doors on the 90.. Installed the door mirror and replaced the mirror glass. Installed the door handles and locks / vacuum pots. Put the entire door harness out of the 94 into both sides.

 

Also took the opportunity to fix an odd hole that had a key lock installed. Probably something to do with that ****ty 1990s era car alarm that was bodged in place.

[ATTACH=CONFIG]78213[/ATTACH] [ATTACH=CONFIG]78214[/ATTACH]

 

To finish off the doors, I need some 1/4" rivets to reattach the window motor I swapped, and a run to picknpull to grab that little plastic retainer that connects thepassenger side lock to the push-pull rods for the power unlock/door knob.. The 90 was missing it, and i broke the one on the 94 unjamming the door.. :(

 

Cheers, Joe

[G60'rado 10]

Work continues.. The plan is to transfer parts as I pull them off, if possible. Stops from creating large piles of parts, and while I can still remember how it all goes back together...

 

Spent the weekend assembling doors, and scrounging for parts.

 

Had to reglue all the door covers, as it had lifted on both sides on all the edges.. Good old solvent based contact cement to the rescue.

 

I did discover that 94 door panels fit the 90 doors with out a problem. On the down side, the inner door handle trim broke one of it's tabs. Does any one know what kind of car these came off of? Mk 2 and Mk 3 Jetta/Golf don't match up.

 

On my quest in the junk yard, I found that the 2000 Passat cabin air filter bracket fits in the gutter perfectly. A couple bolts tack welded from the bottom, and it looks factory..

 

I also found from the another 2001 Passat, a MFA cluster. Would be cool to have the full FIS, but they are worth a fortune, and I don't think ever imported to North America, so fairly rare.

[G60'rado 10]

I haven't fallen off the face of the earth. Work has me away a fair bit, so I pick away when I can.

 

I had a good day on Sunday.

 

Drained both tanks on the 94 and 90.. Nice thing, I don't have to fill the truck for a little while.

 

Finished stripping the back interior out of the 90, and getting the electrics out of the way.

 

Got the fuel tank and entire rear axle assembly out of the 90. And exposed the seams I need to cut on both cars.

 

Next step drop the tank and axle out of the 94..

 

I thought I had a couple pictures on my phone, of the 90 in its sad state.

 

Cheers, Joe

[G60'rado 10]

 

Main part of trunk floor cut out. Now to trim the remaining bits..

 

Then repeat as required on the 94, to extract all of its pieces..

 

Looks like it will have to come out in about 3 - 4 segments.

[G60'rado 10]

Finished stripping the trunk floor out of the 94.

 

Managed to not mangle it too bad separating it from the frame rails. Got alot of welding ahead, but I hope to have it all in by the weekend. Seam sealer, and some touch up paint and it will look factory.

 

 

Spent the weekend working on it again..

 

Finished repairing the pan, and cleaning it up for installation. Cut out the rotten section, and welded some new tin in place.

 

Finished the final touch up on the frame and body, cut the hole for fuel hoses in the wheel well.

 

Just for ****s and giggles, I dropped a couple welds down, so the pan in now attached to the car. I'm going to pick away at spot welding the pan in place over the rest of the week.

 

Hopefully soon, I can move interior over from the 94, the back electrics, and of course, the monster fuel tank which was the reason for all this fun in the first place..

 

Next trick will be replacing the 94's swing arm bushings, one has disintegrated, and the other has turned into "sand".

Edited June 30, 2015 by G60'rado

[G60'rado 10]

It's been a long while since I updated the thread here. The car has not been abandoned or sold for scrap! I regularly update my build thread here. http://www.corrado-club.ca/forum/viewtopic.php?t=15202

 

So here is a years worth of updates.

---------------------------------------------------------

Posted: Mon Sep 22, 2014 12:32 pm

 

Still plugging away.

 

I finished the welding of the trunk floor into place. Cleaned up, and primed the top side.

 

Now to just clean up all the burnt under coating, and weld in the the 2 side pieces, and this project is complete.

 

Looking forward to the massive 75 liter tank in a diesel..

 

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Posted: Tue Dec 02, 2014 1:02 am

 

The punch list:

 

The truck floor is completely welded in, sealed up. The VR6 tank is installed. I combined a Mk 3 TDI inlet fuel screen and the VR6 fuel pump assembly. So it just twists into the bottom of the tank. I also swapped the direction of the float, since the MK4 transmitter is reversed.

 

Finished stripping out the last of the G60 interior.

 

Got a passat B4 glass, and a 97 Jetta sunroof. Stripped the 97 jetta sun roof frame, cleaned it, lubed, and rebuilt it. Swapped the glass to the B4 passat. That got installed today.

 

Took apart the 94 heater box, and cleaned the rats nest out of it. Also cleaned all the ductwork. Got that mounted.

 

Next up, move the wiring from the 94 hatch over, and start reglueing the 94 interior pieces to get them in place. And get the swing arm bushings changed, and the 94 swing arm into the 90.

 

Time to start pulling the front end of the 94 apart. Fenders, supports, engine, hood, wiring.. Use most of the bits as a reference on how the bits on the 90 go back together.

 

---------------------------------------

Posted: Thu Feb 05, 2015 11:58 pm

 

Replaced the bushings and installed the vr6 swing arm. I reused the G60 neuspeed lowering springs on the new monroe vr6 shocks.

Installed new brembo rotors and the mk iv brake calipers.

Figured out the mk iv brake lines on the swing arm.

Installed my new BBS RZ wheels to see how low it sits.

 

Started with swapping the passenger side hatch wiring which led to replacing the entire guts of the hatch. The spoiler motor mechanism was broken, the wiper motor washer tube Ihad broken inside the motor, the plastic lock actuator broke when I tried to remove the hose, and the later lock mechanism had extra wires for the security system (and needed to be changed anyways to match the keys on the rest of the car).

 

In an effort to make some space before ripping into the front end of the 94, I reinstalled the rear carpet, spare tire, back seats, and most of the interior pieces and all seat belts.

Edited June 30, 2015 by G60'rado

[G60'rado 10]

Posted: Wed Mar 04, 2015 3:59 pm

Pictures!

 

I've been migrating my albums over to flickr from cardomain.. Cardomain keeps changing the format and addresses of the pictures..

 

So.. The epic trunk floor swap finale..

 

 

Wearing new shoes.. Atleast in the back. 5 lug BBS RZs, with the 94 swing arm, and 2000 Jetta brakes.

 

 

Rear wiring in place, and ready to connect to the fuse block..

 

Edited June 30, 2015 by G60'rado

[G60'rado 10]

Posted: Fri Mar 27, 2015 12:35 am

Coming down to the end of the parts car.

 

I've stripped the '94 front end down to the engine. Pulled the AC system, the power steering, rad support, removed the heavy Tevs-2 ABS module and clutch cylinders.

 

Next up, pull the remaining wiring, and pull the engine (hopefully it will sell quick).

 

Once the engine is out, the subframe is coming out to be rebuilt (bushings, ball joints), and headed into the 90.

 

--------------------------------------------------

 

Posted: Sun Apr 12, 2015 8:50 pm

Another good weekend..

 

Getting ready to strip out the k-frame from the 94, so I'm pulling all the suspension off of it, so I can take it to the local wand wash, and de-munge-afy it.. The oil/dirt/slime is probably a 1cm thick all over it.. Next up, all new bushings, bearings, ball joints, and struts.

 

And I finished the brake set up on the rear swing arm on the 90. Removed the swing arm for the second time.

 

I welded the tabs for the 2000 jetta brake lines to the swing arm pivots. Cleaned up the caliper lines a bit, and made the chassis side lines fit with a few extra bends to take up some extra length.

 

They fit pretty well, for being 10 years different, and from an entirely diffferent chassis.

 

--------------------------------------------------

 

Posted: Wed May 20, 2015 11:48 pm

Back from my work trip, and am taking the week off to work on the 'rado..

 

Subframe is out of the 94.. cleaned and painted.

 

De-gunged the steering rack.

 

Blasted the knuckles, replaced the wheel bearings, and painted with cast iron paint.

 

Blasted the control arms, and replaced all the bushings.

 

Blasted the backing plates, and painted.

 

Spent today cleaning the engine compartment, and cleaning up the rust under the battery.

 

Next up, drop the G60 suspension, and start piecing the front suspension back together. Also swap the 94 shifter box over while its easy.

[G60'rado 10]

Posted: Wed Jun 10, 2015 10:15 pm

G60 suspension is gone..

 

VR6 K-Frame is in, with a cleaned up steering rack, new boots, and new tierod ends. The cleaned up sway bar, wishbones, and steering knuckles are all installed. As well as a mk3 TDI hydraulic engine mount, and corrado vr6 transmission mounts.

 

VR6 shifter box has been swapped over.

 

Assembled the struts with my lowering springs. Made an adapter plate out of the old g60 spring perch to take the wider g60 spring top.

 

Blasted my Girling 54s, and painted them with VHT silver. I was planning to use the Mk 4 front calipers, but they are a completely different animal. New Brembo rotors, and Honeywell pads.

 

I've read that any front calipers but the mk 4 2.0 (and TDI) should work, so I might go shopping at PnP, and see what I can scare up, so I'm using all mk 4 brake parts.

 

Everything torqued to spec.

 

Also managed to fit the mk 4 TDI firewall heat shield.

 

Next up, start transfering the last of the wiring out of the vr6, and the tdi wiring.

Edited July 3, 2015 by G60'rado

[G60'rado 10]

Picture time!

 

VR6 Rear swing arm. Jetta brakes & lines, new rotors & pads.

 

 

Dropping the nasty g60 k-frame.

 

 

VR6 k-frame and a few cleaned up suspension bits all spiffy.

 

 

Suspension all assembled.. Brembo rotors, Neuspeed lowering springs. New tie rods, wheel bearings, VR6 monroe struts and VR6 strut tops, new control arm bushings, cleaned up VR6 swaybar, Girling 54 calipers.

 

 

And how it sits today..

VR6 shifter, new motor mounts, CV shafts, Jetta heat shield..

 

 

Wiring is still coming out of the VR6, one bit at a time.

[G60'rado 10]

Spent the week roughing in the wiring for the under hood area.

 

Pulled out the old TEVES 2 harness, what a rats nest. Figured out most of the TEVES 20 wiring, and what needs to be spliced into the the CE2.

 

Spent yesterday cutting up the ABS bracket and fabricating a custom one fitted to the car.

 

I wanted to mock everything up to make sure all the custom stuff was going to fit.

 

[sexybourbon 0]

Exellent work mate well done looks like a big project ! Keep plugging away it will be great when its done

[fla 9]

What a superb amount of work. As above it will be really special when completed. I think you should remove the 'rubbish' from your thread title too!

[G60'rado 10]

Thanks for the kind comments.

 

It will be a neat custom when finished. I like doing fabrication and electrical.

 

A 2003 corrado, if vw had ever decided to build them.

[G60'rado 10]

Posted: Wed Jul 15, 2015 3:02 pm

Some new parts have arrived.

 

I got a full FIS cluster from a '02 W8 Passat, for $100 from a US wreckers. Lots of people have flashed the Golf/Jetta 1J0 code on them.

 

As well, some BMW E30 wiper arms. Rumor has it they are direct bolt on, and work far better than the VW 'rado arms. Time will tell.

 

I found an 02 vr6 Passat at picknpull with a full climatronic on it.. Got the heater box, the harness,and the head for $50. It was a little different, the the harness was integrated into the chassis harness, and not standalone. So I had to extract the wiring.

 

 

Now I just need a mkiv standard heater box (the passat is completely different). I had one from the scrapped Jetta, but I binned it :|

 

 

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Posted: Mon Jul 27, 2015 6:09 pm

Worked on the car again this weekend.

 

Puzzling out the climatronic system, and trying to adapt it to the existing heater box. The MKIV box didn't pan out, but donated some bits to the cause.

 

Setup an old version of ELSAWIN so I could get readable wiring diagrams for the 02 passat system. Figured out most of the wiring, except for one wire that goes to the ECU someplace, that isn't on the prints.

 

Powered it up, can move most of the motors, and swing the various doors. The recirc door has been the biggest hassle, mounting the motor is going to be a treat. I did get a different style motor from an AUDI A6, that I will try out. I have about 5 faults that I need to clear up. Ie Canbus, AC pressure sensor, and 3 positioner faults (motors aren't fixed down yet)

 

If the franken-box doesn't work or is unreliable, I'm going to try adding mounts to the audi climatronic box to make it bolt up to the corrado.

 

I'll likely do a how to, Climatronic - The hard way.

 

It's been a good introduction to the VW current flow diagram, as opposed to the north american style wiring diagram that I'm used to.

 

Then I went junkyarding..

The AUDI A4 (1997- 2003?) uses the same heater box, so I ripped out a spare, with motors.

 

A just in Passat W8 (never seen one before at the yard) was dumped, so I stripped off a few sensors for the climatronic that were missing on the GLX i got the system from in the first place. Plus a spare head for the climatronic, and another full FIS instrument cluster (the US one will become a spare/parts).

 

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Posted: Tue Aug 04, 2015 5:43 pm

I've been working at adapting the climatronic to the stock corrado box.

 

Finally figured out the connection for the recirc / fresh flap, using the A6 motor I salvaged last weekend. I get consistant travel without binding on both the recirc and defrost flaps. Lastly will be finish the 2 big flaps, temperature / and face/feet.

 

Also managed to connect/hotwire the system up to my chinese KKL vagcom cable, and do a calibrate on the flap motors using the K-Line diagnostics.

 

I will be looking at registering vagcom lite, and see if it does what I need.

 

Edited August 31, 2015 by G60'rado

[G60'rado 10]

Climatronic modd'd box is in place, and I've started hooking up the electrical system again.

 

I marked most of the wires before I pulled them, so it hasn't been too bad. A few markers have fallen off or got mangled, so I have some reading to do.

 

Biggest whoops so far, I reversed the rear speakers, and had the loom backwards. So I had to take the back carpet out to fix that. But it sorted out 8 mystery plugs.

 

I've started grafting in the climatronic into the stock harness. A simpler system to learn to follow the VW diagrams.

 

After that, strip out the old ECU wiring, and connect the front half of the chassis wiring back into the fuse box.

[dragon green 4]

Love the write ups

Keep the pics flowing