My Corrado G60 to AHU swap.

Lug nuts work too

Noted, great information here. With the proper tools it took me about 30 seconds to pop the remaining injectors out, but I eased them back into place instead of finishing the swap as I had company showing up.

I'll finish this up tonight or Saturday and put the engine back in this weekend. getting so freaking close!

Top preferences for tuners? I know G60ing has a Malone tune...

VWMIKEL of TDTUNING, FTW!

Just dropped the oil pan to replace the gasket and found this- can't be good!

Any ideas what it is?

Thread for that issue here hoping for more traffic:

http://forums.tdiclub.com/showthread.php?t=391134

Looks like parts to the oil pump relief valve to me...check your pump

Kelsey..here is the windage tray gasket that I recommended over the phone...


http://www.germanautoparts.com/productdisplay/55115

Stellar, thanks Chris!

So looking at the oil pump like you mentioned, I'm not sure if there is anything missing - does the busted piece normally live in here?



I'm thinking not, because I can't find any visual differences from the pictures for the one here:

http://www.ebay.com/itm/ENGINE-OIL-...PASSAT-B4-96-97-OEM-028-115-153-/360621834452

New pictures I just took of the oil pump I pulled and disassembled:

Ordered the Oil Pump from IDParts and a windage tray from FCPEuro (never heard of them but they are 20 minutes away from where I work and had it in stock with free shipping to my house, where I wouldnt have to pay sales tax! http://www.fcpeuro.com/)

Hopefully have the parts (and free time) by Wednesday.

Been somewhat bust rather than posting. Engine is in the car but nothing is hooked up. Hoping to do the CV joints, transmission fluid and most of the electrical connections tomorrow.

Got the radiator support welded up this week, as well as some tabs on the bumper rebar. Will post pictures when I can compare them.

Just finally assembled these on the kitchen table, should work great:



Tape with my name- tune from vwmikel (excellent price and communication, had the chip in the mail within 12 hours of payment) mk4 4 bar map, sensor pipe adapter and plug from IDParts... Need time to make progress but things are ramping at work after a lull!

with the oil pump/relief valve trashed, what do the rod and main bearings/journals look like?

Holy wow, first time I've been on here on a PC in a while, sorry about that giant picture - fixed.

Thundershorts, between the bad cam and the oil pump, I would fathom a guess the that engine has seen some oil starvation. So my next thought is that they're not great. I'm going to cross my fingers that nothing catastrophic happens, run this and rebuild the engine that I have sitting in the garage.

My GF had company for the past two weeks which made it hard to spend time in the garage without being impolite. I got some time in there tonight and hope to have the car back on all four tomorrow and getting fluids in it.

I have my tune from VWMIKEL on hand and I just installed the chips in the ECU. Two stupid questions that I can't seem to find the answers to:
1) Do I need an MK4 N75 to run an MK4 MAP sensor? (I'm thinking no)
2) The MK4 MAP sensor goes as close to the intake as possible on the "cold" side, correct?

baja_brewer said:

Holy wow, first time I've been on here on a PC in a while, sorry about that giant picture - fixed.

Thundershorts, between the bad cam and the oil pump, I would fathom a guess the that engine has seen some oil starvation. So my next thought is that they're not great. I'm going to cross my fingers that nothing catastrophic happens, run this and rebuild the engine that I have sitting in the garage.

My GF had company for the past two weeks which made it hard to spend time in the garage without being impolite. I got some time in there tonight and hope to have the car back on all four tomorrow and getting fluids in it.

I have my tune from VWMIKEL on hand and I just installed the chips in the ECU. Two stupid questions that I can't seem to find the answers to:
1) Do I need an MK4 N75 to run an MK4 MAP sensor? (I'm thinking no)
2) The MK4 MAP sensor goes as close to the intake as possible on the "cold" side, correct?

Click to expand...

-You only need mk4 N75 if you are running a VNT turbo and tune.

-MAP sensor gets installed in boost pipe before intake manifold or in intercooler itself, some have mounted it to the intake manifold..

GTiTDi said:

-You only need mk4 N75 if you are running a VNT turbo and tune.

-MAP sensor gets installed in boost pipe before intake manifold or in intercooler itself, some have mounted it to the intake manifold..

Click to expand...

Ah, makes sense about the VNT.

I'll work it into the piping for the time being I think.

Got the CVs hooked back up today and the car is on all fours. I hate doing CV joints, always have. I'm putting the engine compartment back together and got side tracked thinking about how giant the single G60 radiator fan is. I went over to my storage and snagged the double Mk3 fan - its about 2" too short for the G60 Radiator length wise and 2" too tall, so I trimmed the bottom to the base of where the fans hook in and made adapters to extend it. I took some rust off the edges and painted it up, so that will be ready to go in in the morning as I get the other plumbing going.

baja_brewer said:

Ah, makes sense about the VNT.

I'll work it into the piping for the time being I think.

Got the CVs hooked back up today and the car is on all fours. I hate doing CV joints, always have. I'm putting the engine compartment back together and got side tracked thinking about how giant the single G60 radiator fan is. I went over to my storage and snagged the double Mk3 fan - its about 2" too short for the G60 Radiator length wise and 2" too tall, so I trimmed the bottom to the base of where the fans hook in and made adapters to extend it. I took some rust off the edges and painted it up, so that will be ready to go in in the morning as I get the other plumbing going.

Click to expand...

I do have a corrado dual fan u could have

Thanks for the offer. I'll have to see how this one handles the but the mounting seems pretty solid.

Made reasonable progress today. Going to finish wiring the MAP sensor tomorrow (hopefully) and get the inter cooler piping plumbing finished this week.

baja_brewer said:

Thanks for the offer. I'll have to see how this one handles the but the mounting seems pretty solid.

Click to expand...

did I mention the price? $0.00 for TDI club members

Twist my arm then maybe as soon as I can drive the thing up there!

I just threw the frame from a corrado / ecodiesel dual fan into the trash... the motor was bad and the bearing on the "slave" fan was bad too. Should I save it?

-J

compu_85 said:

I just threw the frame from a corrado / ecodiesel dual fan into the trash... the motor was bad and the bearing on the "slave" fan was bad too. Should I save it?

-J

Click to expand...

You were going to throw away classic vw parts??? Don't let Pod hear you say that!
If OP wants a corrado dual fan setup that is in mint working order he can have mine, I'm not too far away..

Something is starting to make me thing you all doubt my fabrication abilities with my retrofitted mk3 fan The change was a spur of the moment thing....

What I really need is a pipe bender... I'm having a hell of a time with my inter cooler piping!

baja_brewer said:

Something is starting to make me thing you all doubt my fabrication abilities with my retrofitted mk3 fan The change was a spur of the moment thing....

What I really need is a pipe bender... I'm having a hell of a time with my inter cooler piping!

Click to expand...

Not doubting your skills..trying to unload some dust collecting clutter!

Sometimes cutting and re-welding the correct angles works too..mandrel benders are not cheap

Spent the evening struggling with some wiring - trying to get the lighting operational while waiting for my final intercooler bits to show up (plus the wiring should be easier w/o pipes in the way.)

This might be a stupid question but I'm going to ask it because its not immediately apparent to me and I don't feel like pouring through the wiring diagrams. If I make sure that the TDI fan Module is hooked up, everything will keep working if I use the Corrado Lighting/Fan harness (yellow fuse box connectors A1, A2, and C), correct?

The wing doesn't work but I'll trouble shoot that later.

Oh, and my POS multimeter kicked the bucket, so I threw it away and bought a mid-range Fluke - just one of those things I've been procrastinating purchasing.

Need a driver side Fog light if anyone has one for a reasonable price

I'm sort of ADD right now, trying to jam to get this done.

I'm using the stock corrado a/c, fan and headlight harness in my car. Now I did have to add in the after-run fan relay (mounts on the fusebox, external to it) and I did have to add the after run temp sensor and wire. I believe the after-run switch and relay are apart of the G60 engine harness. On the G60 its mounts between the intake manifold's plenum and the valve cover. I mounted mine on the intake manifold with a small bracket that was from the G60.



I think the after-run relay is #31. Pay no attention to the aftermarket wire in the picture, I needed a switched power source from the same source that the 109 relay was on and since all OEM output locations were used I decided to tap into the relay instead of a wire.



The cool part about the a/c and fan wiring is that it follows the G60 wiring schematic so its straight forward for trouble shooting.


Good call on the multimeter, it will pay for itself every time you use it.


Update**after typing this in I'm fairly certain I didn't use the factory after-run relay. I think I had sold my harness and I dug thru a box of VW wiring until I found something that was acceptable. Who knows, I bet I will someday if the parts ever fail.

Also my fan cycles on and off in an annoying manner, I should modify the circuit so the fan runs for x number of minutes after turning on. I've not had any issues with my battery, fan or oil coking.

Thanks Frank.

I'm going to go back at it tonight. The HID harness I have was questionable so I rang it out this AM and will borrow a multimeter tonight to try and get the wiring sorted.

Didn't get out of work til late. Got these in the mail!

So is it going to make it this weekend?