US Colorado Corrado

[Absentfaith 10]

Hey everyone, how's it going? Figured I would make a gallery page to help document the overhaul of my new purchase. :)

 

About 2 months ago, an unliscensed driver totaled my daily driver. It was a 99 VW Passat and she was a good little car, but now she cruises that parking lot up in the sky. I put 187k miles on it with no issues besides a new cluth at 165k and an ICM replacement. So having the funds and it being a second car I snatched up a 92 Corrado SLC. Under the hood, it needs some work, but I still have money from the accident, so it's all good. The body is in great shape. Has a small dent in the driver fender (looks like someone dropped a battery on it) and some Colorado sun burn, but for 21 years old, it's in great shape. Interior is pretty good too. The strikers on the doors need to be replaced, but other than that it's about 8/10. Carpet has some wear spots but leather is still good. Spoiler, sunroof, and windows work.

 

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My buddy Pat and I started the odyssey this last weekend with the Bentley manual in hand. It def needs a head gasket so we started there. Gave it a good look over and started writing down all the parts we would need (to start with - I'm sure this will expand as the job continues). Nothing too major, but the more we talked, the more we just decided to overhaul it. Headgasket kit, clutch kit, all new cooling hoses, oil cooler, water pump (metal fins!!!), aux water pump, assorted sensors, thermostat, crack pipe, etc, etc. Hopefully the heads aren't cracked or warped, but we'll see. Spent a bit of money, but since it's from the accident, no big deal. Talked to some VW gurus here in Colorado Springs and found a transmission shop that specializes in euro vehicles. Going to drop the transmission off some time next week for a rebuild. $275.00 (US) for labor plus parts so very fair. It shifted fine when I was driving it, but with us overhauling it, figured we might as well. Hopefully just a soft kit and some cleaning up, but we'll see.

 

I'll post some more pictures on the thread as we move along. Hopefully won't take more than a month or two to finish everything. I wish I had the time to just knock it all out in a few days...but...pesky work. This is the only other picture I have of the bay from when we were about 40 mins into it. It's prety much stripped down to the motor currently. We're going to pull the motor and drop the tranny this Sunday. Can't wait. :)

 

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[Jim 2]

Welcome to the forum :)

[G60radoboi 10]

Welcome. Looks like a decent project you got there and sure it will be bery nice once done.

[Absentfaith 10]

Got all the part in today, minus the oil cooler gaskets and the retaining clips for the hoses on the thermostat housing (old ones didn't have too much spring to them). They should be in tomorrow. Still set to pull the engine and transmission on Sunday.

 

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[scarlet_vr6 0]

Welcome to the forum. Sounds like this one has found a good owner - you seem to be making great progress already! Shame about your Passat (I can well believe the mileage as there is a 99 Passat in my family which isn't far off 230k!) but glad to hear you're making good use of the money. Look forward to seeing how you get on!

[Absentfaith 10]

I thought about buying the Passat back, but they wanted too much for it. Plus the transmission case cracked when it was spun into oncoming traffic and hoped off a few curbs. Yes, it was a nasty one. I figured I had the opportunity to get something I always wanted versus something meh just to get around. Figure with the insurance payout and some of my own money, I'll have something I love and enjoy. Plus, whenever they finish the pending injury lawsuit for the gf, my "half" will more than cover it. I'll take a look at the cams and everything else this weekend too.

[Absentfaith 10]

Do to some issues with cherry picker delivery, the project got pushed out to Monday and Tuesday night. Everything was going smoothly until it came time to connect the chains to the lift brackets. One the two bolts that hold the support bracket in on the backside of the engine was crossthreaded and threw a monkey wrench into the works.

 

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So now after work today I'll have to get a replacement and put it back in with some locktite and let it cure for 24hrs. Didn't want to risk it. Something so small, but a dropped engine would be anything but small. Lol.

 

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This is how she sits at the moment. Saturday and/or Sunday we'll finish pulling it and the transmission. Hopefully it will be nice and easy from there. Stripping and pulling the engine is the hard part, in my opinion. *fingers crossed*

[16VG60 1]

Well done for getting stuck, good to see another Corrado getting the attention it needs. I see in your pic you still have the bumper fitted? I assume you are going to remove this along with the front panel and crossmember? It makes engine and transmission removal a piece of cake.

[Absentfaith 10]

I keep looking at it, but I dunno if we will. There is so much f'n room in front of the engine. We were just going to swing it up and out and put it on the stand off to the right in the empty space (along with the transmission). The transmission is actually already disconnected and just has 1 bolt left connecting it as well as a jack underneath it. It's set to up to be dropped right down. Again, we'll see. I'll def look at that more when I go over there tonight or tomorrow. I'm always open to constructive criticism and pointers to make it easier. :)

Honestly, I was actually surprised at how smoothly it went up to that point. Did have to order some new half axles. The boots on both of them had a nice tear. Pretty much just a "condom" thin membrane left before it's a full tear. Not too bad though. $80 US after the core charge for both. And some idiot cut into and reconnected the starter cable in 2 spots. Why? Probably to hook up the "killler" sound system that looks like a blind man wired it. Cheap fix as well to swap it out with a new one. Also ordered a new oil pan and gasket, metal water pump, new distributor cap, spark plug wires, slave cylinder, and the motor mounts.

[Absentfaith 10]

It's been awhile since I posted an update. The project has been moving along smoothly for the most part so far. Pat and I got the engine out about a week ago.

 

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Here we have Pat with the engine.

 

I dropped the transmission off with the shop last week. I should have an update from them tomorrow to see what the "damage" is going to be. Hopefully just a soft kit. :) *fingers crossed*

 

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Here it is on the engine stand with the timing chain off. Again, was pretty smooth with one hiccup. The bottom aluminum cover plate cracked when we took it off. Even being ever so careful...no luck. So, a little ****ed, but just need to find a replacement one now. We'll see how that goes.

 

Took the the heads off today. Below is a picture of the block with the gasket still on it.

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It's a little hard to see in the picture, but there was def some "white stains" on the gasket, so it was def leaking.

 

Once I took the gasket off, we started inspecting around. It's a wee bit dirty, but overall it's actually pretty good. You can still see the cross-hatching in the cylinders and most of the crud came off pretty easy with a little bit of elbow grease. Tomorrow I'm going to finish cleaning them and get the heads looked at since I have off. They look to be in decent shape, but never hurts to get them checked.

 

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Here's the block with the gasket off before I started cleaning.

 

The timing chain and cams look good. Actually pretty surprised. Supposedly someone rebuilt it at one time, but I call BS on that. I can see the top end being rebuilt, but def not the heads. So going pretty good so far. As long as all goes as planned, going to start putting it back together on Tues or Wed. Then it's on to rewrapping the wires, flush the radiator, put on the new water pump, oil cooler, new clutch and flywheel, etc. It's nice to have some progress. :)

[Absentfaith 10]

Transmission is complete and I'll be picking it up on Monday. Just needed a syncro, bearing, and soft kit. Unfortunately that was 780 bucks (US). But it'll be all nice and pretty. Got the timing chain lower cover yesterday in the mail and should get the clutch alignment tool today or Monday along with the motor mounts. Got the cylinders and heads all cleaned up and looking nice. Started putting it back together 2 days ago. Head gasket, intake and exhaust manifold, and oil pan gaskets put on and torqued to specs. Going to continue putting it back together on Monday and should have it back in the car Tues or Wed of next week.

[big ben 10]

sounds like things are moving along nicely!

[Absentfaith 10]

Thanks. :) Not too bad actually. It's just getting the time to do it all that's been a pain. Everything has been pretty smooth so far. *fingers crossed* I'm going to swap out the axles and wheel bearings tomorrow before we drop it in. I still have some piddly stuff to do like install the new oil cooler, put the alternator, waterpump, oil filter housing, etc back on the block. I also need to finish rewrapping the assorted wire harnesses. Going to do the timing and put on the new flywheel and clutch kit so we can mount the transmission and reinstall it this week. Then it's just a matter of reconnecting everything and installing all the new cooling components. Nothing too too hard, just time consuming. I'm starting to get really excited. Just want to finish it so I can drive it for a bit before my knee surgery next month. :)

 

Trying to upload some more pics but I'll have to do it from home. Doesn't want to upload from work.

Edited May 14, 2013 by Absentfaith

[Absentfaith 10]

So it's been quite awhile but the Corrado is finally done for the most part. Wee!!!! Figured I would post the "final" update with some pictures of the work, etc. I ended up needing surgery on my knee and the girlfriend and her family harassed me non stop about limping around the garage, so that set me back a little bit. That and work. Bloody work. Always gets in the way. But anyway...

 

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Cleaned up pretty well. You could still see the cross hatching in the cylinders. Just cleaned them up by hand with my trusty spoon and some mildish sandpaper (side to side motion! not up and down.) Took a bit of elbow grease. Wanted to do it by hand since I have never done it before. Didn't want to risk screwing up.

 

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Same for the above. Again, took some elbow grease, but didn't turn out too bad.

 

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Transmission back from the shop. It was the most expensive part of the project. The shop only charge me $250 (US) for labor so very fair. Especially when some of the other "less reputable" wanted $600 (US) without even looking at it. Or once of the responses: "A manual? No, we don't work on those." Seriously? The expensive aspect was the syncro kit. $750 (US). As Matt (the mechanic) said, "You can probably get another 2-3 years out of it, but the 2nd gear syncro is def showing some serious wear. Might as well do it now since it's already out of the car." Def would recommend them. Walked me around the shop before hand. Showed my how clean it was, some of their race projects, etc. Very nice. Very clean. And now it shifts like butter. Mhmm....

[Absentfaith 10]

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All cleaned up and back together for the most part. New clutch, pressure plate, and flywheel installed. I took about 2 hours to do the timing. I kid you not. I was so afraid of screwing it up. Got a few DIY from around the wed (here included) and just took my time with it. Started up strong the first turn of the key. I was sweating bullets I was so worried. Never done the timing before. I was afraid it was going to be 1/2 tooth off (just from reading some horror stories) but it runs good. Darn good.

 

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Here we have it back in the car and mounted all proper like. This was about the time I had to have my surgery...so I just had to look at it...and sigh...so close!

 

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Starting to look like a Corrado again. :) Bolted everything down on the front end after this. 3 hiccups, so to speak. That damn thermostat housing...what a colossal PITA. Installed, torqued to spec, and leaked. Reinstalled. Still leaks. Third time was the charm. Took it out, made sure everything was good and liquid gasket and I went to town. No thermostat leaks, but wait! What's this? Bypass connection for the heater core was cracked. That was easy enough to fix. Then the damn hood release cable snapped. $125 bucks here in the states for a new one. No thank you. Cannibalized all the pieces off of it and set it to the side for now. Rigged it so I can open it until I get a bicycle brake cable and rig that up. In the near future. But at least I can drive it for now.

 

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Here's how she sits at the moment. Another issue that came up was for some reason the sticky weights in the wheel well on the driver front was rubbing on the caliper with each rotation. Took them down to my friend's shop and had them balanced with normal tire weights. All good.

 

The only other issue I'm working out now is the oil pressure light coming on and dinging after I hit 2500rpms. (high pressure). The pressure is fine. So, I'm thinking the sensor may need to be replaced? I did have to put a new connection on the wire that runs to it, but should be a good read. I did read that thinner oil can set it off or the FRAM filter? I've got 5W30 in it atm. Any thoughts from anyone?

 

Overall it was fun for the most part. Cost me a little bit of $ from my fun account, multiple scrapes, bruise, burns and 2 finger nails. But overall it was a good time. Most of the time. I have to say though, the Bentley manual was probably my best investment. Lol. $100 (US) on Amazon, but worth every penny. Thanks for looking!