Hi everyone,

Well at long last my TDI conversion is finally under way, forced by the premature demise of my 16V last week  :cry:

On Friday I took the old engine out and cleaned up the bay, and also took out the dash too. Everyone has seen empty engine bays before so no pics of that  

Most of Saturday was spent sorting out the wiring, as I'm using a Golf 3 1Z donor, and the loom needs a fair bit of fiddling with to fit in the 'Rado. The whole lot was wrapped in convoluted trunking, so it's nice and clean and I can get in to it again if needed.

The pedal box also needs modifying, as the TDI is drive-by-wire so the TDI pedal sensor was grafted on to the Corrado pedal assembly. Also the cruise control switches were fitted to the brake and clutch pedals:



I also cleaned up and re-greased the TDI drive shafts (axles). As you can see they're considerably thicker than the 'toothpick' ones from the 16V. They're also nearly new  



I've done a load of other prep-work over the last month or two, but I forget what it all was  :roll:

So by Sunday morning this is what I had:





 :shock:

First thing on Sunday the engine went in with my 'fitting engines for girls without big strong boys and/or an engine crane' method  

The car is on jacks and at it's normal ride height. The engine is on a 6" high trolley:



Roll the engine in to the bay:



It's now sitting higher than the mounts:



Fit the front crossmember and jack the car up until the front mount just fits in place:



Once thats in jack up the car and the engine will sit down on the rear mounts. Put the bolts in and take the trolley out. Nice and easy, no struggling, and no engine crane    

I got the driveshafts and fuel lines hooked up, new short-shifter installed, and a couple of ancillaries, then ran out of daylight   :x

Sunday lunchtime looked like this:



 :?  Either I have waay too much crap on my drive, or I need a bigger driveway!

By the end of today the bay is virtually done, bar radiator and intercooler.



I'm waiting on powdercoated fron subframe and rad support so I'll finish that off when they arrive...

Wiring inside tomorrow, and hopefully I should get it fired up in a couple of days  

Mikki x

good job!

Top-notch!  I wish Mk1's had removable front supports....  I plan on using a similar method as I also have no hoist.  Looks like great work.

Brendan

Removable front is the way to go    It's soooo much easier working on the Corrado than it was on Sciroccos!

Progress today...

I spent most of the morning adapting a mk3 Golf aftermarket aircon unit to fit the Corrado. I swapped the mk3 control box for the Corrado, and then had to tinker for an hour or two to get the fan and evaporator section to fit, as although the Golf unit is similar to the C it's not quite the same  :banghead:



I've not got any of the rest of the system fitted yet, but I thought while the dash was out I might as well put the airbox in. I can finish the rest later  :thumbup:

Put the rest of the water pipes on, and fitted the G60 intercooler:





Oh, and I put the wheels back on  

Not much visible progress today - mostly tinkering with things, changing fluids, stuff like that, but I got a lot of little jobs done  :thumbup:

Electrics tomorrow  

Mikki x

It runs it runs!!!!      

http://www.polov8.co.uk/images/tdi/TDInoises.mp3

There's no exhaust, so it's a bit loud, but the turbo whistle is nice  

Dash back in today then sort out the fuel tank...

Finished hurrah!  

I went out for a test drive this afternoon and bar a couple of niggles it runs very nicely. It's actually quite lively, considering that I've lost 50hp compared to the 16V. Still, chip and nozzles will get me back there and then it will be fun  



Mikki x

the 16V has 140hp?  and 150ft/lbs torque?

Not sure of the engine codes "over there" but if it was the 1.8 "KR" 16v it was 139 HP.  If it was the ABF 2.0 16v, it had 150.   :shock:   Different animal than the "tame" 2.0 16v's we had over here.

I don't think either one of them had that much torque though.

But yes, chip and injectors will wake up that 'Raddo and it will probably be just as fast as it was.  

Brendan

Yes it was the KR with 139bhp. We never got the ABF in the Corrado - only the 9A, which was not much better than the KR  :roll:

The 16V actually has the same max torque as the TDI - 140lb/ft but obviously it comes in much earlier on the TDI. The car actually feels much faster than it was before because the low rpm response is so much better  

Even though it has a few problems I Love driving it! I can't wait 'til it gets chipped  

Whats really bugging me now is a terrible idle that shakes the whole car, and that it refuses to warm up  :x  Ah well I'll get it smoothed out eventually.

Mikki x