baja_brewer
Veteran Member
So I'm finally getting to the point in my swap where I've made enough progress that I feel I can report something - and also were I'll start having some questions! I figured I might as well start my own thread and ask questions inside here or post whatever answers I find to my questions, so that other future swappers can use this like I have used other threads!
Down to business:
- Donor is a '98 Jetta TDI with an AHU - picked it up for a decent price with terminal frame rust. Timing belt was done recently
- Recipient is a '90 G60 Corrado - previous engine was blown and replaced but never got running again. The car is on Porsche twists and has a clean red dot interior. Non-sunroof model, its had a respray and the paint is probably 8/10 at the moment
- Goal is to have it running and driving by the end of July, dailyable by the end of August- then my Rabbit Pickup (1.5NA diesel) will get some rest and some work done to it!
Since the engine was recently "replaced" it came out super easily (at the same time I found a ton of things that pissed me off - had I managed to get it running and drive it as it was it would have been extremely dangerous because the idiot kid I bought it from really half assed the install.) The TDI came out of the donor with a little more difficulty since some parts were fairly rusty - I had to cut the power steering line to get it out (so if I can't use the G60 one I'll have to shell out for a new one)
I've amassed a stock of parts and thought I was good to go - turns out the k-frame has a few places rusted through, plus one of the bolts holding in the a-Arm sheared and I've yet to get that out. Passat 1Z wiring harness out of a B4, B4 pedal cluster, B4 dash cluster, SLC subframe. I'm going to use the cone filter that was attached to the g60 and have a good bit of intercooler pipes on hand. Hoping I can stick with the G60 tank and fuel lines - looking at several solutions for that. I had to cut the flex pipe on the TDI to get it out (it was shot anyway with a gaping hole) and I cut the cat out today and will be piecing those back together.
Wiring has been started but I'm taking that slowly and carefully. The heater core has been replaced and I've ordered all new CV joint and tie rod assemblies since they're easy to replace while its already apart!
Onto the pictures, and then my questions!
As it currently sits:
Engine out of the donor:
Pile of parts:
Sorry, no great shots of the car! The garage is a mess right now and cleaning up is on my to do list before I get back to work- probably the 4th!
Alright, questions- in no particular order:
1) Anyone have some nice quick solutions for dealing with rounded out CV joint allen-head bolts? I need to pick up some more vice-grips before going back at that!
2) Anyone have some nice quick soluitons for jammed on CV joint 30mm nuts on the other side? I'm at the point where I'm ready to take the damn thing to a machine shop and have it drilled out!
3) K-frame: Will any Mk3 k-frame work? from the 2.0? Or just a GLX or any other VR6?
4) Anyone have a part number for this line? As you can see there is a hole in it:
5) Specific things I should do to the engine while its out? As you might be able to see from some of the pictures there is a little bit of surface rust or corrosion here and there, I'm thinking I'll try hand sanding and painting what I can with high temperature paint to try and preserve it as long as possible! Suggestions?!
Any input is welcome! I've ready all the corrado swap threads I could find as much as possible and have the sheet G60ing put together on swaps - but I might need just a little bit more help!
Down to business:
- Donor is a '98 Jetta TDI with an AHU - picked it up for a decent price with terminal frame rust. Timing belt was done recently
- Recipient is a '90 G60 Corrado - previous engine was blown and replaced but never got running again. The car is on Porsche twists and has a clean red dot interior. Non-sunroof model, its had a respray and the paint is probably 8/10 at the moment
- Goal is to have it running and driving by the end of July, dailyable by the end of August- then my Rabbit Pickup (1.5NA diesel) will get some rest and some work done to it!
Since the engine was recently "replaced" it came out super easily (at the same time I found a ton of things that pissed me off - had I managed to get it running and drive it as it was it would have been extremely dangerous because the idiot kid I bought it from really half assed the install.) The TDI came out of the donor with a little more difficulty since some parts were fairly rusty - I had to cut the power steering line to get it out (so if I can't use the G60 one I'll have to shell out for a new one)
I've amassed a stock of parts and thought I was good to go - turns out the k-frame has a few places rusted through, plus one of the bolts holding in the a-Arm sheared and I've yet to get that out. Passat 1Z wiring harness out of a B4, B4 pedal cluster, B4 dash cluster, SLC subframe. I'm going to use the cone filter that was attached to the g60 and have a good bit of intercooler pipes on hand. Hoping I can stick with the G60 tank and fuel lines - looking at several solutions for that. I had to cut the flex pipe on the TDI to get it out (it was shot anyway with a gaping hole) and I cut the cat out today and will be piecing those back together.
Wiring has been started but I'm taking that slowly and carefully. The heater core has been replaced and I've ordered all new CV joint and tie rod assemblies since they're easy to replace while its already apart!
Onto the pictures, and then my questions!
As it currently sits:
Engine out of the donor:
Pile of parts:
Sorry, no great shots of the car! The garage is a mess right now and cleaning up is on my to do list before I get back to work- probably the 4th!
Alright, questions- in no particular order:
1) Anyone have some nice quick solutions for dealing with rounded out CV joint allen-head bolts? I need to pick up some more vice-grips before going back at that!
2) Anyone have some nice quick soluitons for jammed on CV joint 30mm nuts on the other side? I'm at the point where I'm ready to take the damn thing to a machine shop and have it drilled out!
3) K-frame: Will any Mk3 k-frame work? from the 2.0? Or just a GLX or any other VR6?
4) Anyone have a part number for this line? As you can see there is a hole in it:
5) Specific things I should do to the engine while its out? As you might be able to see from some of the pictures there is a little bit of surface rust or corrosion here and there, I'm thinking I'll try hand sanding and painting what I can with high temperature paint to try and preserve it as long as possible! Suggestions?!
Any input is welcome! I've ready all the corrado swap threads I could find as much as possible and have the sheet G60ing put together on swaps - but I might need just a little bit more help!
Last edited: