Gina's TDI Golf Swap
The Crusty Donor
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Look at the Rot
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Left Over Rust
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Just to get the bumper and trailer hitch off
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Crusty Donor Engine
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All timed
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Transfering Timing Marks
The Eurospec Flywheel does not have the TDC Mark so I used the old flywheel to time the motor and then with the Cam lock
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Karman's Ride
The Family Mobile
The $600 Family Car that needed the motor assembled and installed.
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Interior 1.JPG
All sorts of parts were taken off to test other cars, what a headache.
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Trunk full of parts
lots of Misc Pieces. There were duplicates of some parts while other parts were missing.
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Engine 2 with TDI Rado Grill.JPG
This thing had been apart for over a year up at the dealer.
Interior Bad door Panel
The cloth panels were peeling
AEB Crate Motor.JPG
$1,000 Crate motor from VW's firesale. Thank you Checkered Flag VW you rock!!!
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The Engine Almost Done
The Wife wanted the engine to look new so I suggested powder coating the valve cover and intake. She picked the colors.
Port Matched Everything
I port matched the head, manifolds, turbo and throttle body. I'd love to data log the dyno chart to see where its at bef
The Engine Bay is Clean
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What is the Balck Plug For?
Turns out its for the air temp sensor.
Valve Cover Clip
I have no idea what the part number is. Its a good thing I found enough off the junk yard car to get it right. These are
Stainless Steel Hardware too
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I did end up Painting that pulley
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Looks like some of the control arms were repaired under warrenty work.
Intercooler Assembly
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This was missing from the box of parts.
Missing Brackets
These were missing too. Oh by the way I had never worked on a passat before so knowing what I was missing took a lot or
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Many New Parts
There were a lot of new parts put into the motor. Alternator, water pump, thermostat, hardware, flanges and many more.
Touchdown
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I liked working on this install
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New Wheels
Borbet Type E with tires for $600, they only had 5 miles since new way back when.
Rusty Brakes
Don't worry I installed 12" brakes, rebuilt the front and rear calipers and put in Stainless steel brake lines.
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Removing the cloth Panels
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Cut the tabs out
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Break off the remaining Tab
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Do this on all tabs
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Now Lift the Cloth Panel out
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Leather Panel Inserted
After Installing the leather panel insert I used JB weld on each tab.
Leather Panel Inserted
After Installing the leather panel insert I used JB weld on each tab.
Leather Seats Installed
Also you can see the monster mats that picked up for $20
Rear Brakes
I rebuild the calipers, installed new pads, lines and rotors. No problems after 8k miles
Mats, seats and door cards
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12" Front Brake Rotors
The wheel is a little dirty from a bad outer CV.
Bent Wheel
On a trip from Pensacola I bent this wheel on both lips traveling I85. Time to get her repaired.
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Project Good Times
The Build by its Prior Owner
Chassis is completely rust free. Paint is flat black PPG epoxy primer. Picture006.jpg 2007-03-04
Roll Cage
The Cage was done by the 2nd previous owner, a friend of the previous owner. Roll cage built from 1 3/4 DOM tubing. ca
Cage Continued
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More Cage
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Vise Grips were Used :(
The previous owner made a lot of new brake lines due another previous owner with visegrips. Don't ever use vise grips to
New Brake Lines
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Rebuilt Calipers
wheel studs and chromoly lug nuts Picture054.jpg 2007-04-15
Bleeding the new Brakes
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URST Shift Linkage
Eurosport short shifter Picture081.jpg 2007-04-28
Painted Cage and Race Seats
Corbeau Forza race seats Picture058.jpg 2007-04-15
Test Fitting a Dash
This Dash install was never completed and I hope to install one. 2007-04-15
ABA Motor Installed
Can you believe I sold the ABA motor to the guy over a year before I bough the car. He drove from Greensboro NC to pick
TT 2L Mk1 Race Header Installed
ABA 2.0 bottom end (obd1) fresh rebuild, stock JH head fresh valve job, new guides. 288 duration can with with .50
4 into 1 Header
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Header Continued
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100mm vs 90mm
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Flanges
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Flanges
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Rolled Fenders
Fenders rolled front and rear to a tight pinch seam.
Wheels and Suspension
American Racing wheels 15x7 et28 Falken Azenis RT615 99% tread left Picture075.jpg 2007-04-28
Hood & Front Spoiler
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Lights & Grill
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Almost Done
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Looking Good
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Forsale Pic Exterior 1
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Forsale Pics Exterior 3
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Forsale Pics Interior
Wink 5 panel rear view mirror 100_0489.jpg 2005-06-27
Forsale Pics Interior 2
Momo monte carlo steering wheel 100_0487.jpg 2005-06-27
Forsale Pics Engine
early CIS injection (no electronics) 100_0490.jpg 2005-06-27
Forsale Pics Exterior 2
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Forsale Pics Exterior 4
All the rear glass has been replaced with lexan.
Forsale Pics Exterior 5
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Its Mine
Can you really believe I got this for $1,700?
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Spares that Came with the Car
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More Spares
Neuspeed control arm brace Autometer speedo and tach Ground Control coilover set Bilstein PSS9 front coilover s
Spares All Stocked up
I can't believe I got this car with all of the spares on the shelf and there are many other parts that came with the car
Overhead Pic
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Overhad pic of the Engine
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Black & Yellow
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DZSL SLC ALBUM
DZSL SLC
I love having the First in Flight DZSL SLC
The SLC Arriving Home
The car upon arriving home from Tyson's Corner, VA.
Driverside Door Damage
The previous owner had rubbed the door and rocker panel with a concrete pole.
Body Damage Repaired
The hood, ds fender, bumper, ds door, grill and headlights were replaced with silver panels from other corrado VR6s. The
VR6 Motor Repair
This was what the car looked like for a long time. Torn apart!
Head Gasket Work
I bought the car with what was supposed to be just a bad head gasket. So I replaced it. After rebuilding it it ran great
Smoke After the Rebuilds
I finally did the correct thing and measured the bores and they were out of round.
I'm Tired of the VR6 Motor
I thought long and hard about pissing the Vr6 people off by installing a G60. Instead I pissed them off with a TDI.
A TDI Donor Pops Up
This donor was had for $1,250 from Mooresvile, NC.
Lots of Body Damage
It was damaged on all sides of the car. I don't think there were any body pieces that weren't damaged.
More Damage
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112,739 Miles
For a TDI at a reasonable price it had very low mileage.
More Damage
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Axle, Spindle & A-Arm Damage
Both axles were damaged as well as a control arm and spindle.
Axle and Ball Joint Damage
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Loaded UP
I had to jack the car up in the air and drop it on the tow dolly because of the damage.
Repaired, Gutted & Tested
I repaired the car and tested it in may back yard to make certain the transmission and engine were in good condition.
Before the Engine Removal
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All Wires Routed Through Here
The wires from the donor are routed through the rain tray on the mk4 jetta. This lead to the single biggest hassel on th
The Wiring Nightmare
The mk4 wiring is one large harness for the entire car.
The TDI Drivetrain
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The Parts
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The Mad Scientist
This is me the mad scientist.
The Mk4 Brake Booster Mounted
fabbed up two brake booster and pedal clusters before I found a combo that would work. The mk4 brake booster and mk4
Mk4 ABS Swap
To avoid the Check Engine Light (CEL) and to allow for a better daily driver.
The 1st Pedal Cluster
Here are pictures of the first pedal cluster all welded up.
Go-Pedal Mounted
Here's the inital mounting of the drive by wire go pedal (you can't call it a gas pedal on a diesel)
4-bolt Pattern for the Mk4 Brake Booster
The Corrado uses a 3 bolt pattern.
The Mk4 Brake & Go Pedal Bracket
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MK3 TDI Motor Mounts
Initailly I fired the car up with VR6 poly mounts and quickly realised that I would need some soft diesel mounts.
The Rear Motor Mount
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ABA Motor Mount Bracket Carved
One ofthe biggest issues was using the corrado motormount locations and fitting around the low hung MK4 TDI Turbo. I sim
Bracket Modification #2
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Bracket Modification #3
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Bracket Modification #4
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Bracket Modification #5
Mvc-007f.jpg 2006-01-29
VNT Actuator
The actuator sits very close the the motor mount. I had to bend the actuator bracket and the hime joint.
Actuator Fit
Its a close fit but there is no rubbing after nearly 40k miles.
Actuator & Bracket Fitment
Mvc-010f.jpg 2006-01-29
VNT Turbo Reclocked
The compressor housing had to be clocked to point up.
EGR Block Off Plate
The EGR just cloggs the intake manifold so its blocked off for off-road use only ;)
Mk3/B4 TDI Motor Mount Bracket
Here is the Mk3 TDi motor mount bracket that I used.
02A Tranny Bracket
DSC00204.JPG 2007-02-03
Stock Vr6 Tranny Mount
DSC00208.JPG 2007-02-03
VR6 Cables on a 1999.5 02J
The early mk4 02j transmission uses a shifter assembly that is identical to the VR6 O2A transmission's.
Motor Fitted
Mvc-002f.jpg 2006-01-29
Airbox with MAF Mounted
I was able to mount the Mk4 MAF up to the SLC's airbox with the use of an adaptor plate.
MAF Mounting with Backing Plate
DSC00212.JPG 2007-02-03
Airbox Carved Around Fuel Filter
Mvc-005f.jpg 2006-01-29
Filter Mounting
I modified the gas engine's charcoal canister mount to hold the TDI fuel filter.
Fuel Filter Mounted #1
DSC00210.JPG 2007-02-03
Fuel Filter Mounted #2
DSC00209.JPG 2007-02-03
Engine Bay in Feb 2006
Mvc-007f.jpg 2006-02-12
Airbox and engine cover test fit
Mvc-004f.jpg 2006-02-12
Soldering Process #1
This is the process that I performed twice on every wire that need to be lengthened. Only a few needed to be shortened.
Soldering Process #2
Mvc-020f.jpg 2006-05-30
Soldering Process #3
Mvc-021f.jpg 2006-05-30
Soldering Process #4
Mvc-022f.jpg 2006-05-30
Soldering Strength Test
The wire would tear before the joint would fail.
MK4 Aux. Relay Mounting
I mounted the mk4 relays above the corrado fuse panel.
Mk4 Aux Fuse Panel Mounting
The mk4 fuse panel was mounted on the knee bar in front of the evaporator box.
Mk4 Aux Fuse Panel Mounting #2
I had two tabs welded on and I had to clearance the fuse box to clear the HVAC.
Aux Relay Panel Fitment
Mvc-005f.jpg 2006-03-20
The Wiring Fun #1
This is how the car looked for about a year.
The Wiring Fun #2
Picture010.jpg 2006-05-21
The Wiring Fun #3
Picture011.jpg 2006-05-21
The Wiring Fun #4
Picture012.jpg 2006-05-21
The Wiring Fun #5
Mvc-017f.jpg 2006-05-30
The Wiring Fun #6
Mvc-001f.jpg 2006-02-12
The Wiring Fun #7
DSC00220.JPG 2007-02-03
ECU Mounting and more Wiring
I was able to mount the ECU on a G60 ECU bracket.
And More Wiring
DSC00222.JPG 2007-02-03
Outside Air Temp Mounting
DSC00223.JPG 2007-02-03
And more wiring
No holes were drilled in the car for routing of wires. The wiring looks extermly stock because of the routing and the fa
EGR & VNT Valve Mounting
DSC00249.JPG 2007-02-04
Wire Harness & Vac Sensor Mounts
DSC00248.JPG 2007-02-04
Cooling System Module Mounting
DSC00219.JPG 2007-02-03
Work In Progress
Mvc-005f.jpg 2006-02-12
WIP #2
Its a tight fit in this corner.
WIP #3
Mvc-003f.jpg 2006-01-29
Cooling Hoses & Radiator
Swaps always looks so neat until the hoses are installed.
Cooling Fan Temp Switches
The Corrado's switch is on the far right, the Mk3/early mk4 in the middle and the most common mk4 on the left.
Radiator Hose.JPG
Radiator Hose.JPG 2008-08-31
Radiator & Fans Mounted
I used Corrado SLC fans.
Air Pocket
The stock Corrado radiator flange would possible cause an air pocket.
Air Pocket Solved
A custom solution is just a phone call away when you have friends.
Radiator Flange
Mvc-009f.jpg 2006-06-28
Hose Slice with Barbed Fitting
Two hoses needed to be spliced.
Spliced Cooling Hose
DSC00213.JPG 2007-02-03
Corrado Muffler & Mk4 Midpipe
Mvc-005f.jpg 2006-06-09
Mk4 TDI Cat and Mk4 Midpipe
Mvc-006f.jpg 2006-06-09
Corrado Exhaust Hanger
DSC00229.JPG 2007-02-03
Exhaust Welded
I suck at welding. I'm a bugger tack master and then I take them to a professional welder.
Exhaust Welded
DSC00231.JPG 2007-02-03
The Midpipe was Too Short
I needed to lengthen a few pipes.
The Dowpipe Needed an extra 3/4"
DSC00243.JPG 2007-02-04
Mandrel Bends
I bought way too many
The Mk4 Intake Manifold Modifed
Mvc-005f.jpg 2006-06-08
The EGR's Shutdown Flap Fitment
I tried to maintain the EGR assembly because of the shutdown flap. Due to the intake manifold being flipped there was in
Old Navy CCV and SLOWE Racepipe
Here is a custom crank case vent and a custom EGR delete for off road use.
Mk4 Intake Manifold Cut & Welded
Here is what I did to ease the routing of my intercooler pipes.
Preping for a PD Manifold
I bought a European manifold off EBAY.co.uk and in the end I used it on my other TDI Corrado so I could keep the mk4 eng
Mk4 Manifold with PSI Fitting
DSC00239.JPG 2007-02-03
Pressure Fitting Close Up
I used one of the EGR cooler mounts as a bung for a brass fitting.
PD Passat Manifold
the Manifold that I used on he other TDI Corrado. It flows much better. These fetch $300 in the USA. I paid $20 USD plus
PD Hoses Needed
To use the PD manifold I would have needed the hose circled.
The Patient with Work Platform
I mounted some wood on the front of the sub-frame to make it easier while wiring the car.
The G60 Intercooler Mounted
I used a G60 intercooler.
Intercooler Pipe Process
I'm no expert but I had a lot of fun building the IC pipes.
Pipe Fitment #1
Mvc-012f.jpg 2006-06-17
Pipe Fitment #2
Mvc-013f.jpg 2006-06-17
Pipe Fitment #3
Mvc-014f.jpg 2006-06-17
Pipe Fitment #4
Mvc-001f.jpg 2006-06-17
Pipe Fitment #5
Mvc-002f.jpg 2006-06-17
Pipe Fitment #5
MVC-004F.JPG 2006-07-13
Pipe Fitment #6
Mvc-008f.jpg 2006-08-22
Pipes Out of the Car
Kev Lowe welded them for me.
The Transition from the Turbo
the turbo outlet is tiny
Turbo Inlet Pipe
MVC-012F.JPG 2006-08-06
MAP Sensor Mounting
MVC-013F.JPG 2006-08-06
MAP Sensor & Pipe End
MVC-014F.JPG 2006-08-06
Pipe Ends
A bead was welded on the ends of the pipe after this picture was taken.
CCV Inlet
MVC-016F.JPG 2006-08-06
Fuel Tank Inlet Enlarged
There were no diesel fuel tanks available so I enlarged the fuel opening on the corrado's tank. BTW its 18 gallons.
Mk4 vs SLC Fuel Sender
The mk4 unit was too short to use in the SLC's tank. So I used the fuel pump and regulated it down.
Holley Fuel Pressure Regulator
MVC-005F.JPG 2006-08-06
Holley FPR Regulated to 6 PSI
MVC-006F.JPG 2006-08-06
The Return Goes to the Tank
DSC00228.JPG 2007-02-03
FPR Routes to the Tank Vent Port
MVC-009F.JPG 2006-08-06
Tank Vent Port
I used the tank's vent for the FPR's return line.
Modified Mounting in SLC Sending
The Mk4 instrument cluster requires a mk4 resister board in the fuel sending unit. So it had to be customized.
The mk4 sending unit board
Mounted in Corrado SLC's fuel/sending unit.
Mounted
MVC-006F.JPG 2006-12-10
Mounted #2
MVC-018F.JPG 2006-12-10
Natural Empty is Off the Board
The nautal stopping point was off the board.
Delete
MVC-012F.JPG 2006-12-10
Modified Stopping Point
A new stopping point was added and the arm was bent to read correctly.
Stopping Point
Stopping Point#2
Mk4 TDI Cluster Test
Here is the Mk4 cluster all lit up
SLC VR6 Cluster
The stock Corrado VR6 cluster.
Passat TDI Cluster
The cluster that I really wanted to use on this swap. I'm not a fan of the blue lighting for long road trips. Plus I lik
Passat TDI Tach
I ended up using this cluster on my other tdi Corrado.
MK4 Cluster Modified to Fit
The Mk4 cluster is the biggest bear to physically fit in the corrado dash.
The Fittment
It took a lot of cutting, expoxy, and bond to make the cluster look correct.
Lots of Bondo and Grinding
I also had to create a new pelxiglass face.
Not Too Bad
Its not perfect, but it will do.
Factory Gauge Mounting
This is a rare factory part that was sold by Neuspeed. I actually bought 3 of them a year before this project for $30 ea
Almost Done
MVC-001F.JPG 2006-07-13
Almost Done #2
MVC-002F.JPG 2006-07-13
She Drives to a Diesel Pump
Picture034.jpg 2006-11-12
Stock Dyno
it matched eactly what a stock mk4 would dyno at.
Routine Maintenance & UpGrades
DSC00195.JPG 2007-02-02
PP520 Injectors
A healthy upgrade.
Disassembled Again
DSC00226.JPG 2007-02-03
Motor Pulled for the Timing Belt
I pulled the motor to do the timing belt and to check for any fitment issues after racking up 5k miles.
Motor Pulled fr the Belt
DSC00224.JPG 2007-02-03
Timing Belt Routing
DSC00235.JPG 2007-02-03
Delete
DSC00236.JPG 2007-02-03
Locking the Flywheel
DSC00237.JPG 2007-02-03
Locking the Flywheel #2
DSC00238.JPG 2007-02-03
Waterpump with Cracked Impeller
These are a common failure item. Luckily I caught it when I did the timing belt.
Finished #1
DSC00342.JPG 2007-03-01
Finished #2
DSC00344.JPG 2007-03-01
Powder coated IC Pipes
DSC00343.JPG 2007-03-01
Finished #3
DSC00345.JPG 2007-03-01
Canadian VR6 Corrado Wheels
Everybody hates them but I love them.
Finished #4
DSC00346.JPG 2007-03-01
Finished Rear
DSC00348.JPG 2007-03-01
Finished #5
DSC00349.JPG 2007-03-01
Finished #6
DSC00350.JPG 2007-03-01
Finished #6
DSC00352.JPG 2007-03-01
Finished #7
DSC00351.JPG 2007-03-01
Finished #8
DSC00353.JPG 2007-03-01
Finished #9
DSC00354.JPG 2007-03-01
TDI Badge
DSC00356.JPG 2007-03-01
Finished #10
DSC00355.JPG 2007-03-01
First In Flight DZSL SLC
DSC00357.JPG 2007-03-01
TDI Badge & Wheels
DSC00358.JPG 2007-03-01
Delete
DSC00347.JPG 2007-03-01
ABT Wheels #1
I needed some old sckool bling and I think these were the last set sold in America
ABT Wheels #2
I didn't trust my wheel guy. He laughed when he saw the tape.
ABT Wheels #3
DSC00389.JPG 2007-03-14
Up Yours You'll Love It
DSC00427.JPG 2007-03-24
ABT's Mounted #1
DSC00429.JPG 2007-03-24
Larger Turbo #1
I upgraded my turbo shortly after getting this running. It now has an Kerma 1852 turbo.
Larger Turbo #2
DSC00472.JPG 2007-04-21
Turbo Inlet Comparision
DSC00479.JPG 2007-04-21
More Work for the Turbo
DSC00484.JPG 2007-04-21
Turbo, Chip and Injectors
This is the baseline chip after the turbo upgrade. I still need to get remapped to reach the full potential of 170-180wh
New Tail Lights #1
These really update the look of the car.
New Tail Lights Lite Up
DSC00488.JPG 2007-04-25
New Tail Lights Lite Up #2
DSC00487.JPG 2007-04-25
Headlights, Fogs and Turns Lit
DSC00486.JPG 2007-04-25
French Spec High Beams
Yellow high beamsreally light up the road on those dark rainy nights.
Lights Mounted
These lights has sky rocketed in value since I bought mine for $400. They are no longer available and they resell for $8
H&R Coilovers
H&R 1.jpg 2007-05-07
H&R Coilovers
H&R 2.jpg 2007-05-07
ImpexFest Engine Shot
IMG_3300.jpg 2007-05-05
ImpexFest Front
IMG_3299.jpg 2007-05-05
ImpexFest Rear
Corrada_0367.jpg 2007-05-05
Washing #1
DSC00902.JPG 2007-08-24
Washing #2
DSC00901.JPG 2007-08-24
Transmission Build #1
This transmission has a long 3.1 ring and pinion, a Peloquin LSD and a long .68 5th gear.
Transmission Build #2
DSC00818.JPG 2007-07-17
Transmission Build #3
DSC00817.JPG 2007-07-17
Transmission Build #4
DSC00819.JPG 2007-07-17
Transmission Build #5
DSC00821.JPG 2007-07-18
VW Vortex's Waterfest 13 Coverage #1
1258__scaled_600.jpg 2007-12-08
VW Vortex's Waterfest 13 Coverage #2
886.jpg 2007-12-08
VW Vortex's Waterfest 13 Coverage #3
1262.jpg 2007-12-08
VW Vortex's Waterfest 13 Coverage #4
1257.jpg 2007-12-08
VW Vortex's Waterfest 13 Coverage #5
887.jpg 2007-12-08
VW Vortex's Waterfest 13 Coverage #6
894.jpg 2007-12-08
WaterFest 13 Staging Lanes #1
wf13_14.jpg 2007-12-08
WaterFest 13 Staging Lanes #2
wf13_16.jpg 2007-12-08
Drag Racing Carnage
The 1st time at the track had no issues but the track was not prepped well. The 2nd time was test and tune for some big
Drag Racing Carnage #1
DSC01096.JPG 2007-11-02
I was Spotted by a Vortexer on my trip to Ohio
BTW I got 900 miles on my way back while traveling at a good clip on the interstates.
Best Tank EVER 1,000 Miles
I drove to Pensacola from Norfolk VA on one tank of fuel and got 56mpg. AFter thinking about it I could probably push fo
DSC01891.JPG
DSC01891.JPG 2008-08-11
DSC01894.JPG
DSC01894.JPG 2008-08-11
DSC01890.JPG
DSC01890.JPG 2008-08-11
DSC01892.JPG
DSC01892.JPG 2008-08-11
DSC01893.JPG
DSC01893.JPG 2008-08-11
CFVWGTG0606014.jpg
CFVWGTG0606014.jpg 2008-06-06
Neuspeed Bracket.JPG
Neuspeed Bracket.JPG 2008-11-23
Neuspeed Bracket (1).JPG
Neuspeed Bracket (1).JPG 2008-11-23
TDIs Them (TDI SM)
Finished....yeah right is what The Wife says
DSC_3766[1].JPG 2008-09-29
The first recipient, not used
The paint was very faded and the seals were very tired.
1st Rado Not Used Passenger Side
DSC00593.JPG 2007-05-17
1st Rado Not Used Front Quarter
DSC00595.JPG 2007-05-17
1st Rado Not Used Rear DS Quarter
DSC00591.JPG 2007-05-17
1st Rado Not Used Rear PS Quarter
DSC00594.JPG 2007-05-17
1st Rado Not used Front
The paint was very faded and the seals were very tired. Turns out the car has been in at least one accident
1st Rado Not used Rear
The paint was very faded and the seals were very tired.
The Donar
Some NC friends hooked me up with this great deal. It was on Craigslist for all of 20 minutes when I made an offer witho
The Minor Damage
The TDi people thought I was crazy to part it out. I did have to replace the control arm, spindle and wheel to get it on
Looks Pretty Good
DSC00726.JPG 2007-06-09
Front
DSC00729.JPG 2007-06-09
All Cleaned up
Before I left the town where I bought her I spent $10 at the car wash.
Milage
This is a fairly low milage drivetrain
Bring the Recipient Home
"The Wife" is driving the DZSL SLC home behind me in my just aquired Silver G60 Corrado.
Its like a Double Mint Gum Commercial
DSC00863.JPG 2007-08-04
I love It
DSC00865.JPG 2007-08-04
The Reciepient
A 59k mile 1990 G60 Corrado with original silver paint. I almost dropped the TDi into a White car that was very tired a
Lots of Unimportant Problems
The Car was at the dealer for: sunroof, window regulator, heatercore, & A/C a total estimate was roughly $4k hence why I
The Engine was Perfect
Despite the list of problems the cond. of the engine, paint & blk leather was perfect.
The Interior was Perfect
Even the crappy US spec belts work properly.
Did I say Low Milage?
Believe it or not this is my 2nd 59k Rado that I've had in the past 4 years.
The Motor Cleaned Up Well
Like all cars I buy the first thing I did was clean the drivetrain
Less then 24hrs After Purchase
I yanked the G60 motor as soon as she cooled off.
No More G60
I Yanked the G60 motor as soon as she cooled off.
All of the plugs were still in the Holders
This is very rare.
More Original Plugs
DSC00872.JPG 2007-08-04
What a filthy Engine Bay
DSC00877.JPG 2007-08-05
All Cleaned Up
DSC00878.JPG 2007-08-05
Passat TDI Pedals and Wiring
These parts fit the Corrado much better then the Jetta parts
Drive by Wire Go-Pedal #1
DSC00738.JPG 2007-06-15
Drive by Wire Go-Pedal #2
DSC00736.JPG 2007-06-15
Drive by Wire Go-Pedal #3
DSC00737.JPG 2007-06-15
Go-Pedal Plug
DSC00740.JPG 2007-06-15
Drive by Wire Go-Pedal #4
DSC00739.JPG 2007-06-15
Clutch Pedal Differances
Here is the Rado's pedal on the left and the Passt TDI on the right.
The Clutrch Pedal Wows
Rado's Clutch master cylinder is $75 vs $150 for the Passat's hence the swap.
Pedal Cluster #1
DSC00883.JPG 2007-08-11
Pedal Cluster #2
DSC00882.JPG 2007-08-11
Pedal Cluster #3
DSC00903.JPG 2007-08-24
Pedal Cluster #4
DSC00905.JPG 2007-08-24
Pedal Cluster #5
DSC00906.JPG 2007-08-24
Pedal Cluster #6
DSC00904.JPG 2007-08-24
Pedal Cluster #7
DSC00907.JPG 2007-08-24
I yanked the Dash and HVAC
The cool part is that everything is plug and play when compared the the DZSL SLC
I enjoy wiring
The fun part is that the mk3 TDI into a Rado is plug n play.
Glow Plug Relay 103
I used a 1996 TDI Passat Harness which used the 103 glowplug relay. The Harness also required the removal of the 5 injec
Glow Plug Module
I didn't want to screw up the wiring order so here is a pic
All New Front End Parts
KYB shocks&struts, Ball Jts, Tie-rod ends, Strut Bearings&VR Neuspeed Springs
R32 Control Arm Bushings
All front end parts where replaced and these are an upgrade when compared to the swiss cheese corrado bushings.
Neuspeed Springs
Neuspeed Suspension
Bushings Installed
DSC01196.JPG 2008-03-01
Mk3 TDI K-Frame Installed
DSC00891.JPG 2007-08-18
Shift cable Ends
DSC00892.JPG 2007-08-18
HVAC Parts
I swapped the TDI Evap into the G60's HVAC Parts so the a/c lines would bolt right up.
Evaportator Comparison
The TDI has a single bolt holding the lines in. The G60 lines thread in.
All New Foam in the HVAC Box
Installed new foam, so it would work properly & not blow foam in your eye
HVAC Foam #2
DSC00913.JPG 2007-08-28
HVAC Foam #3
DSC00911.JPG 2007-08-28
HVAC Foam #4
DSC00916.JPG 2007-08-28
HVAC Foam #5
DSC00915.JPG 2007-08-28
HVAC Foam #6
DSC00914.JPG 2007-08-28
Fuel Filter Mount #1
DSC00920.JPG 2007-09-01
Fuel Filter Mounting #2
DSC00922.JPG 2007-09-01
Fuel Filter Mounting #3
DSC00923.JPG 2007-09-01
Fuel Filter Mounting #4
DSC00921.JPG 2007-09-01
Mk3 tank too close to the door
I will have to swap in a Corrado tank... I have but I don't have any pictures. I did have to use the G60's fuel pump bec
The MK3 Tank's spout is longer
DSC01190.JPG 2008-03-01
The Garage Mess
DSC00944.JPG 2007-09-03
Its Coming Together
DSC00945.JPG 2007-09-03
G60 Fan Shroud with a SPAL Fan
I Love the install of this
I only had to trim the lip
of the fan shroud for a 12" Spal fan to clear it.
I also trimmed the studs off
DSC00969.JPG 2007-09-23
SPAL Fan Specs
DSC01397.JPG 2008-03-30
Engine Shot
I first used the stock TDI Jetta IC Pipes but they blew off too much during the test drives.
Eco-Diesel Airbox
Installed with Silicone hoses. This Airbox was very difficult to hunt down.
Traditional N75 Vacumn Line Colors
DSC01194.JPG 2008-03-01
A/C Hose by Bill Smith's A/C
Bill Smiths in Yorktown VA does great custom hoses. The G60 hose needed a diff end.
A/C Lines Routed
DSC01629.JPG 2008-06-13
A/C Expansion Valve
DSC01631.JPG 2008-06-13
Moonroof Installed
The whole interior had to come out of the car.
The fabric is a perfect match
DSC01186.JPG 2008-03-01
The Dash Reassembled
DSC01187.JPG 2008-03-01
The Passat TDI Cluster
I bought this for the DZSL SLC but couldn't use it.
Its so clean
DSC01185.JPG 2008-03-01
Dash/Center Gauges #1
DSC01416.JPG 2008-03-31
Dash/Center Gauges #2
DSC01417.JPG 2008-03-31
20AE/337/GLI Pedals
"The Wife" requested them
Techtonics Borla Exhaust #1
This is a $20 junkyard Borla Exhaust score from a year or two ago.
Techtonics Borla Exhaust #2
I installed a new mid-pipe
Corrado SLC Exhaust Tip
I scored the tip over 5 years ago and needed a car for it.
Goodies
Tails, Side Markers, Euro-PD Manifold, and Pedals
www.eurowires.net light Harness
The best eurolight retrofit harness EVER. I have made them but his are PERFECT.
TDI Timing Bealt Tear
This was found after 2 short test drives while I was replacing the timing belt. Thank goodness the IC pipes kept blowing
Advance to towards the Block and the retard is in Front
DSC01669.JPG 2008-06-19
Timing Prior to Advancement
DSC01670.JPG 2008-06-19
Tails
They are smoked less then the DZSL SLC's.
Lights Installed
DSC01387.JPG 2008-03-27
The New Wheels
Voxx MG 16x7 with an ET 20
Wheels Installed #1
DSC01404.JPG 2008-03-31
Wheels Installed #2
DSC01403.JPG 2008-03-31
SIlver TDI Comparison
DSC01405.JPG 2008-03-31
Wheels Installed #3
DSC01409.JPG 2008-03-31
Wheels Installed #4
DSC01407.JPG 2008-03-31
Wheels Installed #5
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Wheels Installed #6
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Wheels Installed #7
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Wheels Installed #8
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Wheels Installed #9
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Wheels Installed #10
DSC01414.JPG 2008-03-31
Wheels Installed #11
DSC01415.JPG 2008-03-31
Misc Engine Shot #1
DSC01632.JPG 2008-06-13
Misc Engine Shot #2
N75 Valve
Misc Engine Shot #3
DSC01633.JPG 2008-06-13
Misc Engine Shot #4
DSC01634.JPG 2008-06-13
Misc Engine Shot #5
DSC01637.JPG 2008-06-13
Misc Engine Shot #6
DSC01639.JPG 2008-06-13
Misc Engine Shot #7
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Misc Engine Shot #8
DSC01648.JPG 2008-06-14
PD Intake Manifold Installed #1
DSC01628.JPG 2008-06-13
PD Intake Manifold Installed #2
DSC01636.JPG 2008-06-13
EGR Race Pipe Delete #1
DSC01640.JPG 2008-06-13
EGR Race Pipe Delete #2
DSC01641.JPG 2008-06-13
EGR Race Pipe Delete #3
DSC01642.JPG 2008-06-13
ECU Vacumn Leak #1
DSC01675.JPG 2008-06-25
ECU Vacumn Leak #2
DSC01676.JPG 2008-06-25
ECU Vacumn Leak Repair
DSC01677.JPG 2008-06-25
PP764 Injectors Installed with an UpSolute Chip
This is a Horrible Combo
IC Pipes Round Two #1
They still need to be powder coated in blk wrinkle for the OEM look.
IC Pipes Round Two #2
DSC01718.JPG 2008-07-04
Both TDI Rados #1
DSC01712.JPG 2008-07-04
Both TDI Rados #2
DSC01713.JPG 2008-07-04
Both TDI Rados #3
DSC01711.JPG 2008-07-04
Both TDI Rados #4
DSC01715.JPG 2008-07-04
Both TDI Rados #5
DSC01714.JPG 2008-07-04
Both TDI Rados #6
DSC01716.JPG 2008-07-04
European Engine Cover
I have this cover in transit from Germany where I won in on Ebay.de for $35 usd shipped.
The US Spec Cover
It would require a mount to be welded to the intake manifold. Also it requires 3 nuts to be removed to inspect the engin
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DSC01899.JPG
DSC01899.JPG 2008-08-14
DSC01895.JPG
DSC01895.JPG 2008-08-14
DSC01896.JPG
DSC01896.JPG 2008-08-14
DSC01897.JPG
DSC01897.JPG 2008-08-14
DSC01898.JPG
DSC01898.JPG 2008-08-14
DSC01919.JPG
DSC01919.JPG 2008-09-07
Audi TT WHeels with H&R Coilovers
DSC01953.JPG 2008-09-21
Dumped
DSC01960.JPG 2008-09-21
DSC01954.JPG
DSC01954.JPG 2008-09-21
DSC01955.JPG
DSC01955.JPG 2008-09-21
DSC01957.JPG
DSC01957.JPG 2008-09-21
DSC01956.JPG
DSC01956.JPG 2008-09-21
DSC01958.JPG
DSC01958.JPG 2008-09-21
DSC01959.JPG
DSC01959.JPG 2008-09-21
DSC01963.JPG
DSC01963.JPG 2008-09-23
wwh2o2008-49.jpg
wwh2o2008-49.jpg 2008-10-07
wwh2o2008-213.jpg
wwh2o2008-213.jpg 2008-10-07
wwh2o2008-48.jpg
wwh2o2008-48.jpg 2008-10-07
wwh2o2008-214.jpg
wwh2o2008-214.jpg 2008-10-07
H20 Garage.JPG
H20 Garage.JPG 2008-09-26
IMG_0918.jpg
IMG_0918.jpg 2008-10-21
DSC_3776.jpg
DSC_3776.jpg 2008-09-29
DSCF3103.jpg
DSCF3103.jpg 2008-09-28
070.jpg
070.jpg 2008-09-28
frankstdicorrado.jpg
frankstdicorrado.jpg 2008-09-25
lineofvws.jpg
lineofvws.jpg 2008-09-25
franktdi-1.jpg
franktdi-1.jpg 2008-09-26
mk1rocco.jpg
mk1rocco.jpg 2008-09-25
sideview-2.jpg
sideview-2.jpg 2008-09-26
DSC00224.jpg
DSC00224.jpg 2008-09-28
DSC00183.jpg
DSC00183.jpg 2008-09-26
DSC_3758.jpg
DSC_3758.jpg 2008-09-29
DSC_3759.jpg
DSC_3759.jpg 2008-09-29
DSC_3761.jpg
DSC_3761.jpg 2008-09-29
DSC_3762.jpg
DSC_3762.jpg 2008-09-29
DSC_3763.jpg
DSC_3763.jpg 2008-09-29
DSC_3764.jpg
DSC_3764.jpg 2008-09-29
DSC_3766.jpg
DSC_3766.jpg 2008-09-29
Stainless H&R 1.JPG
Stainless H&R 1.JPG 2008-11-12
Stainless H&R 5.JPG
Stainless H&R 5.JPG 2008-11-12
Stainless H&R 2.JPG
Stainless H&R 2.JPG 2008-11-12
Stainless H&R 3.JPG
Stainless H&R 3.JPG 2008-11-12
Stainless H&R 4.JPG
Stainless H&R 4.JPG 2008-11-12
DSC02206.JPG
DSC02206.JPG 2008-12-25
DSC02223.JPG
DSC02223.JPG 2008-12-25
DSC02207.JPG
DSC02207.JPG 2008-12-25
DSC02208.JPG
DSC02208.JPG 2008-12-25
DSC02209.JPG
DSC02209.JPG 2008-12-25
DSC02210.JPG
DSC02210.JPG 2008-12-25
DSC02211.JPG
DSC02211.JPG 2008-12-25
DSC02212.JPG
DSC02212.JPG 2008-12-25
DSC02213.JPG
DSC02213.JPG 2008-12-25
DSC02214.JPG
DSC02214.JPG 2008-12-25
DSC02215.JPG
DSC02215.JPG 2008-12-25
DSC02216.JPG
DSC02216.JPG 2008-12-25
DSC02217.JPG
DSC02217.JPG 2008-12-25
DSC02218.JPG
DSC02218.JPG 2008-12-25
DSC02219.JPG
DSC02219.JPG 2008-12-25
DSC02220.JPG
DSC02220.JPG 2008-12-25
DSC02221.JPG
DSC02221.JPG 2008-12-25
DSC02222.JPG
DSC02222.JPG 2008-12-25
Test fit of a Dual Oil Filter Mount
DSC02331.JPG 2009-02-19
DSC02333.JPG
DSC02333.JPG 2009-02-19
DSC02332.JPG
DSC02332.JPG 2009-02-19
1996 Passat 1Z ECU
DSC02295.JPG 2009-02-16
1998 Jetta AHU ECU
DSC02296.JPG 2009-02-16
Neuspeed Rear Strut Bar
Converted it for Fast removal
Neuspeed Triangulated Rear Bar 2
Converting it for Fast removal
Neuspeed New Bracket
Replaced the fixed bracket found on the bar from Neuspeed.
AutoTech Strut Bar Pieces
I will be purchasing some new aluminum tubing and building a custom fit strutbar that looks as good as it fits.
OBD2 VR6 Cluster modified for the TDI #2
With the Correct mileage for the chassis 000_0035.jpg 2010-08-01
B5.5 VNT GT1749VA vs Mk3 GT15 #1
000_0055.jpg 2010-09-08
GT1749VA & AFN Manifold #1
000_0049.jpg 2010-09-08
Mk3 AFN downpipe New From EBAY.co.uk
Mk3 AFN downpipe.JPG 2010-11-14
DSC02783.JPG
DSC02783.JPG 2010-12-11
EGR Work #1
DSC03513.JPG 2011-04-09
EGR Work #2
DSC03516.JPG 2011-04-09
EGR Work #3
DSC03519.JPG 2011-04-09
DSC03312.JPG
DSC03312.JPG 2011-03-06
DSC04101.JPG
DSC04101.JPG 2011-05-20
DSC04100.JPG
DSC04100.JPG 2011-05-20
Rear Stress Bar Install
DSC04091.JPG 2011-05-20
EGR Valve Installed 2
DSC04088.JPG 2011-05-15
Honing the Cylinders 2
DSC04117.JPG 2011-05-21
Honing the Cylinders 7
DSC04123.JPG 2011-05-21
Checking the Ring Gap 5
DSC04129.JPG 2011-05-21
DSC04132.JPG
DSC04132.JPG 2011-05-22
DSC04167.JPG
DSC04167.JPG 2011-05-28
DSC04170.JPG
DSC04170.JPG 2011-05-31
DSC04176.JPG
DSC04176.JPG 2011-05-31
DSC04180.JPG
DSC04180.JPG 2011-06-01
DSC04309.JPG
DSC04309.JPG 2011-06-10
DSC04310.JPG
DSC04310.JPG 2011-06-10
DSC04355.JPG
DSC04355.JPG 2011-06-11
DSC04360.JPG
DSC04360.JPG 2011-06-11
DSC04366.JPG
DSC04366.JPG 2011-06-11