Day 3&4

First off was continuing to work on modifying the frame rail,

I've removed the orginal battery mount and will be putting the battery into the trunk to give more room for the intercooler piping.

Speaking of piping here is a new piece I just grabbed.

I've decided to go with a smaller inlet Audi intercooler as it will fit better. The rear main seal has been replaced, and the motor is ready for the pressure plate, clutch plate and flywheel to be installed. The old motor mounts are gone and new polyurethane ones are ready to be installed.

Heres a shot of the old engine out and on the ground, all parts that where need have been stripped off.

Oh and another cool toy has been added to the motor...

Day 5

Well the new motor is hooked back up to the tranny with a new 16v pressure plate, clutch plate and a lightened and balanced flywheel. Finished the mod's in the engine bay and have given is a fresh coat of high temp semigloss black.

Spent the morning trying to find a 15' battery cable and a pulley for the waterpump...came up empty on both. DOH! But have no fear I'll figure something out. Tomorrow the motor goes back in and then the fun job of redoing the wiring. Also I'll be starting to plumb the intercooler.

Day 6

Here is the motor with the tranny connected on the hoist ready to go in.

the engine bay all painted and ready to recieve the engine.

And now with the motor in!

A frontal shot with the intercooler in it's mocked up location.

The nice new Poly engine mounts.

Shot of the frame rail mod with the pulley tensioner in place.

Yes not the prettiest welds, it's been a while since I've done any welding.

Day 7

Was able to find a long enough battery cable today, and a friend got me the correct pulley for the waterpump so I'm good to go on those two fronts.

Mounted the wiper fluid bottle,

tied down the fuel line a little better,

finished the worked on the intercooler plumbing.

Then started routing the new wiring harness, blending it in with what it left of the old one. I still need to finish that job and neaten it all out, as well I need to build a box to mount the battery in the trunk.

Even though I not quite finished yet there are a few people I'd like to thank for helping me along the way.

First my buddy Mike for letting me use his garage to do the swap in and helping getting the old engine out. Joe for coming over and adding an extra hand during the removal. Phyl for putting a days work and letting me use her car to pick up parts. My brother Michael and my Dad who helped me put the new motor in. Retro_mike of Vortex fame, who not only got me the motor, but has been of great help sorting out the wiring, finding some of the little items that are hard to come by. My son's Jarod and Tyler who each have had thier hands in the engine bay at one time or another. Oh and of course my Mom...who keep me going with care packages of food and caffine.

Day 8

Well another long night, but a productive one. Got all the wiring done with the exception of the power relay for the ECU, but I do have the wires run for that just need to connect them. Finished the intercooler plumbing, ran the connections for all the gauges, got the battery power line to the back of the car and completed of the vacuum lines.

So what I have left to do it mount the battery, find a ground to the chassis for it, wire up the new gauges, install the vacuum gauge for the ECU and wire it's relay, re-install the drive shafts, install the waterpump pulley and the drive belt then fill her with fluids...the crank it!

Day 9

Well I did not get much done tonight as I'm too tired from the late night yesterday. I did get the AirFuel gauge and the Oil Temp gauges wired up, ran the wiring for the ECU relay and the vacuum line for the ECU.

The wonderful mess of wiring.
and more wiring...
and more...
the new gauge cluster I made.

Day 10

Nope didn't get it started tonight!

Where to start, the dealership(it gets better)gave me the wrong sized bolts for the water pump pulley, not a major probem as I have more. Next I start to install the accessary belt, (still gets better)dealership gives met the one for the Corrado...too small. So I spent almost 2hrs sourcing the right one out,find it and install it. The I had to replace the viscosity boot on the passengers inside joint, wrong size...this time too big(we're not done yet)from the dealership. So okay put the old one back on for to get the car going and replace it on the weekend. The only three parts I by from the Dealership and there all wrong. To top off all the things that screwed up tonight, I broke the friggin car keys and I haven't been able to find my spares yet!

But there is some positive that came out of tonight, I learned...don't buy from the DEALERSHIP!

But also I got the battery mounted in the trunk,

fully dressed up the wiring in the engine bay.

Adjusted the piping from the intercooler to the throttle body, I didn't like the way it was bending. Adjusted one of the spring clamps on the lower rad hose which was threatening to rub against the oil cooler hose. Tightened the header bolts and hooked the header up to the rest of the exhaust system. Check that power was making it to the front of the car, it was. Engine is now completely ready for fluids.

That was it for the evening! Goodnight!

Day 11

Well she turned over eventually!

Well if finished off the last of the wiring, double check all the connections, nuts, bolts and clamps. Filled her up with fluids, connected the battery and cleared away engine bay of all tools, hardware, rags and anything else that should not be there.

Turned the key...nadda thing!

rechecked the wiring...missed one wire to the starter motor!

Turned the key...she cranks put thats it.

put a volt meter in the fuel pump and crank again...nadda!

Check the wiring again...DOH missed the switched power to the fuel pump relay.

Turned the key...she cranks, the fuel pump primes, but...nadda

check that the fuel lines are not mixed up...nope thier good.
check that fuel is coming out the line...yup.
check for spark...nadda
check for power going to the coil...yup
check for power coming out of coil...hmmmmmm should see more than 0.48 of a volt
check resistance on the terminal....woooho way too much!
coil is Dead

I have a spare but it is in storage and it's too late (now 1am) to get it...so she waits until tomorrow after work.

My buddy Mike who is letting me use his garage for the swap and who has done the metal fabrication for me.

The G-Lader

The new Tach

Cold Air intake

Adjustable Cam gear

Yes it's a original iMac speaker, works great!

The Valve Cover