Fourtitude.com - 3.6 24v is going in the Corrado!
Username or Email Address
Do you already have an account?
Forgot your password?
  • Log in or Sign up

    Fourtitude.com


    Page 1 of 9 12345 ... LastLast
    Results 1 to 25 of 220
    1. Member
      Join Date
      Jul 4th, 2016
      Location
      Palmyra, PA
      Posts
      245
      Cars
      2014 FiST, 92 Corrado 3.6
      07-06-2018 12:38 AM #1
      Hello All! I finally got my swap car to try my hand at this swap. 2006 Passat 4mo w/149k on the clock. I'll pretty much be following the blueprint G60ING and the contributors there have laid out and find my own ways to solve certain problems along the way.

      The Corrado is a 92 SLC so its a dizzy VR6 with 210k on it, 10lb flywheel, K&W V2's, BBS Montreals. Other than that, pretty much stock.





      So the order of operations will be to get that 3.6 out of the passat so I can do a lot of work to it before I even touch the Corrado. The 3.6 leaky, might as well change a lot of seals, chains, guides, headgasket, valve seals, etc whiles its out. I also want to keep driving the Corrado while the weather is nice


      Things to figure out:

      1.) Accessory drive. I know I need 24v VR6 accessory bracket w/mk4 tensioner pulley. Since I am starting with an SLC I believe my AC Compressor, water pump and PS pump are fine

      2.) Crank pulley. Either figure out what machining needs done to make the OEM part work or Fluidamper Passat crank pulley should work..will update later

      3.) Clutch and flywheel: I really like the lightweight flywheel I currently have. Not sure is that is a good route to take here. But, being that the engine is ~270ft-lbs at the crank, a stage 2 SB rated at 325ft-lbs would probably be enough and SB conservatively rates their stuff. Clutchmasters doesn't list torque values for their clutches so I may shoot them an email to see what they would recommend. Leaning Clutch Masters FX300 and having the old flywheel resurfaced

      4.) Transmission: Would a bolt kit in the diff be enough? Or just bite the bullet on a wavetrac LSD? I'm certainly looking for advice on this one. Car will be street driven only, not launched hard. But pulls to 6k+ will happen.

      5.) Oil cooler: Stock? Or go down to a smaller mkIV one? Going Stock with a pie cut front engine mount

      6.) Swap software: Is there any big differences between UM and Malone on this? I know I at least need IMMO defeat and coding for 2 OS2 sensors vs 4...


      I'm sure I'll think of more...
      Last edited by choobs; 07-22-2018 at 10:26 PM.
      Former username: Magics5rip

      Corrado 3.6 build thread

    2. Remove Advertisements

      Advertisements
       

    3. Member G60ING's Avatar
      Join Date
      Jun 27th, 2000
      Location
      Annapolis Area MD
      Posts
      15,728
      Cars
      2010 3.6 4-Motion CC, 1990 G60/TDI/R36 Corrado
      07-06-2018 08:37 AM #2
      Quote Originally Posted by choobs View Post
      Things to figure out:

      1.) Accessory drive. I know I need 24v VR6 accessory bracket w/mk4 tensioner pulley. Since I am starting with an SLC I believe my AC Compressor, water pump and PS pump are fine

      2.) Crank pulley. Either figure out what machining needs done to make the OEM part work or Fluidamper

      3.) Clutch and flywheel: I really like the lightweight flywheel I currently have. Not sure is that is a good route to take here. But, being that the engine is ~270ft-lbs at the crank, a stage 2 SB rated at 325ft-lbs would probably be enough and SB conservatively rates their stuff. Clutchmasters doesn't list torque values for their clutches so I may shoot them an email to see what they would recommend.

      4.) Transmission: Would a bolt kit in the diff be enough? Or just bite the bullet on a wavetrac LSD? I'm certainly looking for advice on this one. Car will be street driven only, not launched hard. But pulls to 6k+ will happen.

      5.) Oil cooler: Stock? Or go down to a smaller mkIV one?

      6.) Swap software: Is there any big differences between UM and Malone on this? I know I at least need IMMO defeat and coding for 2 OS2 sensors vs 4...

      1) not sure, I’ll let you write that book but why not do the higher amp alternator. Plus it fits better. Ac compressor I agree. The tensioner and PS is where the questions really sit.

      2) You can use the Passat pulley.

      3) That 325lb might not be enough. Remember you are doing a tuning and exhaust work to the

      4) Bolt kit and reinforce the roll pin in the diff. The roll pin fails more than anything.

      5) Use the stock 3.6 cooler, I tried to do the 12V one and after going back and forth after fitting it I decided the space gained by the 12V wasn’t worth it.

      6) Nobody has dynoed the Malone tune yet. In the 3.6 FB Group John Levine has been doing some dyno testing of tunes.

      Mine isn’t that far along. Mine had a rev hang but Mark Malone has been working to tune it out. My Buddy’s son just did a auto to manual swap in he B6 4motion with a Malone tune and Mark has almost completely fixed the rev hang. I think I’m probably near 295whp and after some tweaks I’ll be north of 300 and maybe 320 with cams.
      Last edited by G60ING; 07-06-2018 at 08:45 AM.

    4. Member
      Join Date
      Jul 4th, 2016
      Location
      Palmyra, PA
      Posts
      245
      Cars
      2014 FiST, 92 Corrado 3.6
      07-22-2018 10:25 PM #3
      Made some progress today, I'm dead tired but it was well worth the effort! Picked up a 24V accessory bracket and belt tensioner and also ordered a bunch of seals to start getting this old motor back in shape.

      Below is a list of ordered parts so far, still need to get a timing chain kit, head bolts, and water pump..I'm sure there is more outside of that I'll need

      I've also started a google spreadsheet of parts with OEM part numbers. 3.6 Parts List



      Ordered parts

      Intake mani seal - lower 03H133237D
      valve cover seal 03H103483E
      rear main 021103051C
      front main 022103151D
      valve stem seals (x24) 36109675A
      head gasket 03H103383K
      oil cooler seal - inner 038117070A
      oil cooler seal - outer 038 117 070
      knock sensor 030905377C



      Last edited by choobs; 07-22-2018 at 10:29 PM.
      Former username: Magics5rip

      Corrado 3.6 build thread

    5. Remove Advertisements

      Advertisements
       

    6. Member 02tt225's Avatar
      Join Date
      Sep 13th, 2007
      Location
      Harriman NY
      Posts
      1,101
      Cars
      '77 Golf, '04 R32
      07-22-2018 11:17 PM #4
      Good luck man.

    7. Member G60ING's Avatar
      Join Date
      Jun 27th, 2000
      Location
      Annapolis Area MD
      Posts
      15,728
      Cars
      2010 3.6 4-Motion CC, 1990 G60/TDI/R36 Corrado
      08-01-2018 10:46 AM #5
      Quote Originally Posted by 02tt225 View Post
      Good luck man.
      Nice work on the parts list, if only Kept every one of those that I've put together.

    8. Member
      Join Date
      Jul 4th, 2016
      Location
      Palmyra, PA
      Posts
      245
      Cars
      2014 FiST, 92 Corrado 3.6
      08-05-2018 05:52 PM #6
      Got the engine on my Jegs 1000lb stand. I ditched the 4 arms and drilled the plate out for the rear motor mount points. That way I have access to the front and rear of the motor...

      Got the 24V bracket and alternator sorted, changed out the water pump, stripped the timing covers and valve cover, ordered a bunch of timing parts. Everything looks clean inside the motor but I'm going to just do the chains and guides while I'm here. Between FCP and ECS I was able to put together a decent near complete mostly OEM VW kit for $270. Oh and did a ton of cleaning since this lump of iron is GRIMY. Next on the list is to take the head off and start cleaning out those gross intake ports!


      Timing parts and numbers (the only part I didn't buy is the pin on the upper guide #071 109 515)

      Timing Chain - Lower 03H109465 Iwis
      Timing Chain - Upper 03H109503 Iwis
      Chain Tensioner Rail - Lower 21109467 Iwis
      Chain Tensioner Rail Upper 03H109509A VW
      Timing Guide - lower 21109469 VW
      Timing Guide - Upper 03H109513B VW
      Guide Pin Lower 21109471 VW
      Chain Tensioner - Upper 03H109507 VW
      Guide Pin upper 066109511D VW
      Guide Rail Upper 066109514A VW
      Oil pump bolt N10404404 VW
      Tensioner Bolt - upper N10613901 VW
      Tensioner Bolt - lower N90923801 VW

      accessory bracket





      Timing and cams



      Former username: Magics5rip

      Corrado 3.6 build thread

    9. Member G60ING's Avatar
      Join Date
      Jun 27th, 2000
      Location
      Annapolis Area MD
      Posts
      15,728
      Cars
      2010 3.6 4-Motion CC, 1990 G60/TDI/R36 Corrado
      08-05-2018 09:26 PM #7
      Nice progress

    10. 08-06-2018 04:45 PM #8
      nice work! let the fun begin

    11. Member
      Join Date
      Jul 4th, 2016
      Location
      Palmyra, PA
      Posts
      245
      Cars
      2014 FiST, 92 Corrado 3.6
      08-07-2018 12:36 AM #9
      Got this heavy lump off the block. I'd like to get this to a machine shop soon in case there is a longer than normal wait time on turn around. In the meantime, I can focus on stripping the engine harness, accelerator pedal, ecu, fuel pump, FP control module, fuel lines and such.

      It looked like there was some leaking starting into one of the cylinders so this was certainly a good thing to do while the motor is away from the car.



      also tried to capture the timing marks on the cams as best I could. Timing on the crank pulley was set to TDC on cyl #1 by the normal marking convention



      Former username: Magics5rip

      Corrado 3.6 build thread

    12. Member G60ING's Avatar
      Join Date
      Jun 27th, 2000
      Location
      Annapolis Area MD
      Posts
      15,728
      Cars
      2010 3.6 4-Motion CC, 1990 G60/TDI/R36 Corrado
      08-07-2018 10:52 AM #10
      I have my own opinion on decking a vr6 head and that as little as possible should be taken off and the reason being is that timing chains won't be easy to get right with the head being shorter than it was before. It would be cool if VW had different thickness of head gaskets like they do for TDIs for VR6s to make up for machining of the head. When I build my next engine I might try not to deck the head and just use copper sealant on each side of the HG rather than risk a shop taking too much material.

      I had a bramble VR that I rebuilt the head (and decked it) on and it never ran 100% perfect after decking the head and I have always suspected the shop took too much and it caused all sort of minor issues related to the deck height. I sold that car for a huge loss to the next owner with huge disclaimers and he continues to drive it with odd running behaviors.
      Last edited by G60ING; 08-07-2018 at 02:26 PM.

    13. Member
      Join Date
      Jul 4th, 2016
      Location
      Palmyra, PA
      Posts
      245
      Cars
      2014 FiST, 92 Corrado 3.6
      08-07-2018 06:17 PM #11
      Thanks for the reply G60ING, I didn't consider a lot of that. I know I have not decked VW heads in the past and used the copper spray to good results. Something else I didn't consider was compression ratio. This motor is already 12:1, not sure how it would be able to cope with more compression.

      All this said, I think I like the copper spray/no decking option so I'll most likely go that route. Which means that maybe I can put this thing back together this weekend
      Former username: Magics5rip

      Corrado 3.6 build thread

    14. Member
      Join Date
      Jul 4th, 2016
      Location
      Palmyra, PA
      Posts
      245
      Cars
      2014 FiST, 92 Corrado 3.6
      08-12-2018 06:59 PM #12
      Making more progress. I had intended on changing out that valve stem seals but the angle of the valve springs wasn't really accommodating my el cheapo valve spring compressor, so I ditched that idea and instead bought a Himalayan Freight media blaster and some fine walnut media (24 grit.) I saw G60ING had posted in his thread about having luck with it so I gave it a go myself. The valve on the gun isn't the best but it did force me to upgrade some stuff on my compressor and get an inline condensation filter.

      Results: not bad. I could have spent more time with it but I figured I took years worth of build up out of these runners so its still a win. I had also soaked the runners in seafoam which helped loosen up some of the heavier chunks. I can see the valve and the guide, good enough for now I suppose.



      Cams, caps and lifters stripped from the head



      I ended up turning the cams by hand to open the intake valves and scrape more crud off. So much buildup on the valves...



      Lets put the head back on already!



      Heads on and torqued up. I need to wait for a special tool to keep the HPFP gear from turning however this must be a tool for only the early BLVs. I saw Nater I believe have a tool to hold an oblong shaft but my HPFP just has the hole for that shaft. Instead, I have to wait for this special tool which was of course twice as much as the oblong shaft one. VW Audi Valve Timing Adjustment Tool T10332.

      Last edited by choobs; 08-12-2018 at 07:08 PM.
      Former username: Magics5rip

      Corrado 3.6 build thread

    15. Member G60ING's Avatar
      Join Date
      Jun 27th, 2000
      Location
      Annapolis Area MD
      Posts
      15,728
      Cars
      2010 3.6 4-Motion CC, 1990 G60/TDI/R36 Corrado
      08-13-2018 10:55 AM #13
      Last edited by G60ING; 08-13-2018 at 11:01 AM.

    16. Member
      Join Date
      Jul 4th, 2016
      Location
      Palmyra, PA
      Posts
      245
      Cars
      2014 FiST, 92 Corrado 3.6
      08-13-2018 09:35 PM #14
      Question regarding timing:

      My intermediate shaft gear is 180 degrees out from the 7:00 position. I think this shaft only controls the oil pump but 180 deg out should be fine. Can anyone confirm that? Also, I have the intake camshaft adjuster turned all the way counter clockwise for the timing marks to line up.

      Crank pulley mark is still on the block mark. Crank gear tooth is lined up with where the case splits.





      Still waiting on the tool, but this is pretty close to correct I think.
      Last edited by choobs; 08-13-2018 at 09:38 PM.
      Former username: Magics5rip

      Corrado 3.6 build thread

    17. Member G60ING's Avatar
      Join Date
      Jun 27th, 2000
      Location
      Annapolis Area MD
      Posts
      15,728
      Cars
      2010 3.6 4-Motion CC, 1990 G60/TDI/R36 Corrado
      08-13-2018 11:07 PM #15
      Rotate the crank 360*

    18. Member
      Join Date
      Jul 4th, 2016
      Location
      Palmyra, PA
      Posts
      245
      Cars
      2014 FiST, 92 Corrado 3.6
      08-13-2018 11:45 PM #16
      Quote Originally Posted by G60ING View Post
      Rotate the crank 360*
      Looks like the IM shaft rotates 90 degrees clockwise for each crank rotation, so it took 2 full rotations. In any case, oil sprocket mark lines up now
      Former username: Magics5rip

      Corrado 3.6 build thread

    19. Member
      Join Date
      Jul 4th, 2016
      Location
      Palmyra, PA
      Posts
      245
      Cars
      2014 FiST, 92 Corrado 3.6
      08-15-2018 08:54 PM #17
      A nice little reference for torque specs just for the timing components and all the timing mark locations

      http://replace-timing-belt.com/how-t...i-r36-4motion/
      Former username: Magics5rip

      Corrado 3.6 build thread

    20. Member jddaigle's Avatar
      Join Date
      May 30th, 2003
      Location
      Denver, CO
      Posts
      7,068
      Cars
      2008 Passat Wagon VR6 4motion, 2013 FIAT 500 Sport
      08-17-2018 04:51 PM #18
      Quote Originally Posted by choobs View Post
      A nice little reference for torque specs just for the timing components and all the timing mark locations

      http://replace-timing-belt.com/how-t...i-r36-4motion/
      Awesome reference! I'm going to add it to the Resource Thread.
      - Jeff
      B6 Passat 3.6 & 4motion Resource Thread
      Now: 2008 VW Passat 3.6 4motion Wagon, 2013 Fiat 500 Sport
      Then: 1987 Volvo 745GLE, 1989 Volvo 745GL, 1994 Volvo 940T, 1995 Infiniti G20, 2000 VW Passat 1.8T, 2001 VW Jetta Wolfsburg Ed (x2), 2004 VW Golf TDI, 2006 Jetta TDI

    21. Member
      Join Date
      Jul 4th, 2016
      Location
      Palmyra, PA
      Posts
      245
      Cars
      2014 FiST, 92 Corrado 3.6
      08-26-2018 11:38 PM #19
      Been getting side tracked will all the stuff around the house I should have been doing instead of tinkering with my toys...

      anyway, new parts aquired are:

      ARP flywheel bolts
      ARP diff ring gear bolts
      Clutch Masters FX350 clutch/pressure plate
      CE2 relay and fuse sockets from G60ING (thanks man!)
      New Beetle OBDII port
      MSD Tach Adaptor

      Today I did at least take the oil pan off to check the oil pickup and make sure everything looks right. Upon inspection I found that this gasket/screen from the vvt housing must have fell out when I was disassembling the head...



      Sigh. This means all the timing covers came back off, cam adjusters, top chain and guide/tensioner and then it all needed put back together...again. But at least the problem was found before the motor went in the car and I kind of wanted to reseal the lower timing cover again since some oil had leaked on to the mating surface that didn't get cleaned off. So it should be all around better at this point

      Tomorrow im going to do my best to get the Corrado's engine/trans out mostly to get that flywheel out and off to the machine shop to be surfaced. If the planets align, I can have it back for the 3 day weekend at least have the motor sitting in the car...we'll find out! Option 2 is to just order an OEM flywheel since they are like $60.
      Last edited by choobs; 08-27-2018 at 12:12 AM.
      Former username: Magics5rip

      Corrado 3.6 build thread

    22. Member
      Join Date
      Jul 4th, 2016
      Location
      Palmyra, PA
      Posts
      245
      Cars
      2014 FiST, 92 Corrado 3.6
      08-27-2018 07:07 PM #20
      Woo! Parts!

      Former username: Magics5rip

      Corrado 3.6 build thread

    23. Member
      Join Date
      Jul 4th, 2016
      Location
      Palmyra, PA
      Posts
      245
      Cars
      2014 FiST, 92 Corrado 3.6
      09-03-2018 05:45 PM #21
      Well I got about half as far as I wanted which considering that its 90 and super humid out, I'll take it! We are at the no turning back point now...

      10# flywheel going to the machine shop this week for resurface, motor should be 100% ready to go in the car soon. The trans, however, still needs torn apart so probably a few weeks before everything is at least sitting in the car. Fingers crossed!




      Former username: Magics5rip

      Corrado 3.6 build thread

    24. Member G60ING's Avatar
      Join Date
      Jun 27th, 2000
      Location
      Annapolis Area MD
      Posts
      15,728
      Cars
      2010 3.6 4-Motion CC, 1990 G60/TDI/R36 Corrado
      09-03-2018 08:19 PM #22
      Check the runout on the flywheel where the ring gear sits

    25. Member
      Join Date
      Jul 4th, 2016
      Location
      Palmyra, PA
      Posts
      245
      Cars
      2014 FiST, 92 Corrado 3.6
      09-03-2018 10:51 PM #23
      Quote Originally Posted by G60ING View Post
      Check the runout on the flywheel where the ring gear sits
      I'll ask the shop if they can do that for me, thanks!

      I'm also thinking about going the LSD route. The trans already needs torn apart and the added power is just going to make the stock diff behave worse. I may also look for a shop to do this for me since I don't have a way to check pre-load...
      Former username: Magics5rip

      Corrado 3.6 build thread

    26. Member ceese's Avatar
      Join Date
      Jul 2nd, 2011
      Location
      Seattle
      Posts
      2,683
      Cars
      Audi A3 3.2 quattro sLine 2008, Lava Gray
      09-04-2018 01:34 AM #24
      How many miles are on the 3.6? While you have it apart you may want to replace the gasket in the cylcone chamber in the valve cover. It's a stupid thing to have fail after all your hard work.
      __________________________________________________ _______________
      Anyone who looks at the Audi A3 3.2 DSG and sees an overpriced economy car should not be allowed to play with Rottweiler puppies.
      Robert Farago, The Truth About Cars

    27. Member
      Join Date
      Jul 4th, 2016
      Location
      Palmyra, PA
      Posts
      245
      Cars
      2014 FiST, 92 Corrado 3.6
      09-04-2018 10:12 AM #25
      150k on the motor. I thought I had read about the oil cyclone giving people issues at high miles but I could never find additional information on the topic. I think the Autotech guys just replaced the whole valve cover to get a new oil cyclone. I removed mine and took a look at it but I didn’t see any replacable seals...
      Former username: Magics5rip

      Corrado 3.6 build thread

    Page 1 of 9 12345 ... LastLast

    Posting Permissions

    • You may not post new threads
    • You may not post replies
    • You may not post attachments
    • You may not edit your posts
    •