Volkswagen Corrado G60
Discussion
A very busy Easter weekend on site and dealing with an incident yesterday meant I only got to the handle investigation today.
Here are the pair for comparison where you can see the difference in the striker pins:
The plan was to drill out the pin holding the striker and just swap it over. Unfortunately, it wasn't as simple as that...
There are other differences to the handles (I suspect the replacement Passat handle is a cheap knock off which won't help).
The mount for the locking mechanism as well as the mechanism itself are slightly different.
Fine, I'll remove the circlip and swap them.
Oh wait, the spring that is crucial to the operation of the handle is also different.
Ok, I'll swap that as well with the old spring.
Oh, the body of the Passat handle by the striker is slightly (2mm) thicker so it won't work without filling it down....
Oh, and the metal piece that had also failed in the old handle is different in he new one, but should still work right....
At this point however, I did what I should have done in the first place. Extricate the metal part from both, and just swap the new one for the broken one and then resemble the old handle with this part in it. I only realised this of course having spent hours tackling each new obstacle!
It was one of those jobs that needed a lot of unconventional tools and a bit of lateral thinking. I used a cheap cycling chain link splitter, g-clamp with and without the flexible foot, picks, punches and a drill. In truth though, I could have done without the drill if it's chosen the correct course of action in the first place of course.
In the end though, it's now assembled and back on the car, and the door handle action is the best it's ever been since I've owned it! Good thing too given the time and effort, but I'm pleased the repair was only £8 not £70+
Here are the pair for comparison where you can see the difference in the striker pins:
The plan was to drill out the pin holding the striker and just swap it over. Unfortunately, it wasn't as simple as that...
There are other differences to the handles (I suspect the replacement Passat handle is a cheap knock off which won't help).
The mount for the locking mechanism as well as the mechanism itself are slightly different.
Fine, I'll remove the circlip and swap them.
Oh wait, the spring that is crucial to the operation of the handle is also different.
Ok, I'll swap that as well with the old spring.
Oh, the body of the Passat handle by the striker is slightly (2mm) thicker so it won't work without filling it down....
Oh, and the metal piece that had also failed in the old handle is different in he new one, but should still work right....
At this point however, I did what I should have done in the first place. Extricate the metal part from both, and just swap the new one for the broken one and then resemble the old handle with this part in it. I only realised this of course having spent hours tackling each new obstacle!
It was one of those jobs that needed a lot of unconventional tools and a bit of lateral thinking. I used a cheap cycling chain link splitter, g-clamp with and without the flexible foot, picks, punches and a drill. In truth though, I could have done without the drill if it's chosen the correct course of action in the first place of course.
In the end though, it's now assembled and back on the car, and the door handle action is the best it's ever been since I've owned it! Good thing too given the time and effort, but I'm pleased the repair was only £8 not £70+
Lovely job, looks like a proper puzzle to get it right and see which pieces from the donor would be most efficient. These are the kind of jobs that, as you have pointed out, would cost way too much to have done by someone else, and validate all the knowledge you've built up over the years.
@Spinakerr, thank you. It does make it seem worthwhile when it all goes back together smoothly (no matter how long it's taken!)
With the door handle fixed and the car roadworthy again, they meant I could go out on site.... It's a rare thing to take the Corrado to work, we're usually supplied with a tracked, limited (possibly auto) diesel, always in white and suitably adorned in company livery. These really are white goods and are terribly dull to drive, so this made a nice change!
It also managed to highlight another issue that needs fixing... My colleague in the car behind pointed out that he thought my exhaust was hanging a little low, and sure enough, when we got to the next site, there was a scraping noise as I parked up....
(No the bridge isn't in good condition, but yes, the arch profile is mostly as built).
Despite being on the supplied hanger rubbers, it looks like that adapted 16v exhaust needs a touch more attention to get it just so!
The fuel economy reading on the MFA was also suspiciously low (20mpg} suggesting a problem with the vacuum line at the back of the clocks. Good job they needed to come out anyway in the eternal hunt for what is causing the needles to flicker!
With the door handle fixed and the car roadworthy again, they meant I could go out on site.... It's a rare thing to take the Corrado to work, we're usually supplied with a tracked, limited (possibly auto) diesel, always in white and suitably adorned in company livery. These really are white goods and are terribly dull to drive, so this made a nice change!
It also managed to highlight another issue that needs fixing... My colleague in the car behind pointed out that he thought my exhaust was hanging a little low, and sure enough, when we got to the next site, there was a scraping noise as I parked up....
(No the bridge isn't in good condition, but yes, the arch profile is mostly as built).
Despite being on the supplied hanger rubbers, it looks like that adapted 16v exhaust needs a touch more attention to get it just so!
The fuel economy reading on the MFA was also suspiciously low (20mpg} suggesting a problem with the vacuum line at the back of the clocks. Good job they needed to come out anyway in the eternal hunt for what is causing the needles to flicker!
Good to see you can use it daily. I'm using mine as a daily after losing my other car a while back.
I do sometimes think it's a case of "if it isn't one thing, it's another" with Corrados. I noticed on Friday that when I switch from headlights to side lights, the headlights stay on until I move the switch to no lights at all. When I turn them on again the switch works correctly, going from side lights to headlights.
Keep at it!
I do sometimes think it's a case of "if it isn't one thing, it's another" with Corrados. I noticed on Friday that when I switch from headlights to side lights, the headlights stay on until I move the switch to no lights at all. When I turn them on again the switch works correctly, going from side lights to headlights.
Keep at it!
gforceg said:
Good to see you can use it daily. I'm using mine as a daily after losing my other car a while back.
I do sometimes think it's a case of "if it isn't one thing, it's another" with Corrados. I noticed on Friday that when I switch from headlights to side lights, the headlights stay on until I move the switch to no lights at all. When I turn them on again the switch works correctly, going from side lights to headlights.
Keep at it!
Ah the dodgy headlight switch, indeed a common Corrado issue. My brother's Corrado vr6 had a funny five minutes the other day where the electrics went a bit odd, engine idle was like a cammed V8, the windscreen wipers only working on the fastest setting but still really slow, headlights misbehaving, indicators.I do sometimes think it's a case of "if it isn't one thing, it's another" with Corrados. I noticed on Friday that when I switch from headlights to side lights, the headlights stay on until I move the switch to no lights at all. When I turn them on again the switch works correctly, going from side lights to headlights.
Keep at it!
Turned out the bloody garage who had it for a few weeks due them not being able to order the right bloody part had flattened the battery and then just placed the terminals back on so the earth was barely touching. Corrados are very voltage sensitive!!!!
OP, you can get the tank straps new for VW heritage or nice shiny chrome ones as well (just make sure you get the right ones as G60 and VR6 fuel tanks are different) ,a chap on ebay sells new stainless bolts for £6.50 if you do want to do anything about the tank.
As for the exhaust hangers, I find that the standard rubbers barely last a few years with a standard exhaust because that "suitcase" silencer weighs a tonne. There are upgraded exhaust rubbers that have a metal chain inside them to give them much more rigidity or polybush ones
I ended up changing my hangers to the later style bar ones which use much thicker rubber mounts and with a stainless system minus the suitcase silencer have not had any issues since.
As always thanks for the useful information all. I'll take a look at the tank straps when I investigate the exhaust further. That likely to be when I've finished painting the car shelter for the Morris, so some time next year at this rate....!
Still, as it was forecast for heavy rain this afternoon, I took a break from the painting and did a brief wash and polish and the most minor of jobs. The rear badge holding grommets. The originals has disintegrated, and I'd used motorbike fairing panel pins as a temporary measure (there was gaffer tape involved).
This made the badge stand prouder than I was happy with, so I spent 10 minutes post polish setting it back to rights:
Much better!
It's the little things that make you smile
Still, as it was forecast for heavy rain this afternoon, I took a break from the painting and did a brief wash and polish and the most minor of jobs. The rear badge holding grommets. The originals has disintegrated, and I'd used motorbike fairing panel pins as a temporary measure (there was gaffer tape involved).
This made the badge stand prouder than I was happy with, so I spent 10 minutes post polish setting it back to rights:
Much better!
It's the little things that make you smile
A few quick updates...
I obtained powerflex bushes for the exhaust, however I managed to hang them wrong in the first instance so the exhaust still rubbed on the rear beam. Blast.
Old rubbers definitely needed replacing though:
... and the new ones look much better:
I also decided to tackle the leaking heat exchanger /oil cooler. Knowing that these fail and mix water and coolant, and having spotted emulsified oil previously, this seemed like a good idea.
Grill off, bumper off, oil cooler out:
There it is:
Could I do it without draining the cooling system...? Could I heck.
New versus old:
Wait a moment, what do you mean they haven't put a bloody gasket in the box? But the car is up on stands with no oil or coolant in it!
Time to improvise....
After a lot of searching and swearing, I finally found an acceptable alternative. The spare filter from a six cup stovetop espresso maker. Well, I know it will cope with temperature and pressure!
Also tweaked a couple of the hangers on the centre box to get it a bit higher :
New air filter, oil and filter and coolant recycled back in (it is only 6 months old) and time for a test drive.
Bloody brilliant fun, I remember why I love this car on damp bits of the ring road! The exhaust isn't rubbing any more either... for at least 30 minutes. Arse.
Time to see if powerflex will honour that lifetime warranty....
I obtained powerflex bushes for the exhaust, however I managed to hang them wrong in the first instance so the exhaust still rubbed on the rear beam. Blast.
Old rubbers definitely needed replacing though:
... and the new ones look much better:
I also decided to tackle the leaking heat exchanger /oil cooler. Knowing that these fail and mix water and coolant, and having spotted emulsified oil previously, this seemed like a good idea.
Grill off, bumper off, oil cooler out:
There it is:
Could I do it without draining the cooling system...? Could I heck.
New versus old:
Wait a moment, what do you mean they haven't put a bloody gasket in the box? But the car is up on stands with no oil or coolant in it!
Time to improvise....
After a lot of searching and swearing, I finally found an acceptable alternative. The spare filter from a six cup stovetop espresso maker. Well, I know it will cope with temperature and pressure!
Also tweaked a couple of the hangers on the centre box to get it a bit higher :
New air filter, oil and filter and coolant recycled back in (it is only 6 months old) and time for a test drive.
Bloody brilliant fun, I remember why I love this car on damp bits of the ring road!
The exhaust isn't rubbing any more either... for at least 30 minutes. Arse. Time to see if powerflex will honour that lifetime warranty....
Edited by darkyoung1000 on Monday 20th July 07:10
Thanks for the comments all, nice to combine my love of cars and coffee, although perhaps not in the way originally planned....
chrismc1977, nice to know its not just me I suppose.... Really not impressed with them as the second one on the centre mount went today as well. I'm going to refit the old rubber ones tonight as a temporary measure.
In better news, the run out from York to Filey today didn't leave any puddles under the car, so the power of the coffee gasket has been tested! It was also absolutely lovely to watch it being driven along sweeping roads! A couple of things struck me - it's still handsome (yes I'm biased); it's really not that large compared to modern cars; and it's not slow for in great acceleration.....
I was watching because I was on this newly acquired machine:
Absolutely marvellous run out!
chrismc1977, nice to know its not just me I suppose.... Really not impressed with them as the second one on the centre mount went today as well. I'm going to refit the old rubber ones tonight as a temporary measure.
In better news, the run out from York to Filey today didn't leave any puddles under the car, so the power of the coffee gasket has been tested! It was also absolutely lovely to watch it being driven along sweeping roads! A couple of things struck me - it's still handsome (yes I'm biased); it's really not that large compared to modern cars; and it's not slow for in great acceleration.....
I was watching because I was on this newly acquired machine:
Absolutely marvellous run out!
Edited by darkyoung1000 on Tuesday 21st July 07:26
Yup, really not impressed with the powerflex bushes and I'll be seeking a refund....
Both of the ones supporting the front of the box have broken, and it was a combination of cable ties and good fortune that made it last the run back from Filey.
As I'm on site tomorrow (no access tracks fortunately), I had to carry out a temporary repair, so jacked it up in the street and put the old rubber ones (and the thick cable ties) back again.
Not pretty, but it will do for now :
Both of the ones supporting the front of the box have broken, and it was a combination of cable ties and good fortune that made it last the run back from Filey.
As I'm on site tomorrow (no access tracks fortunately), I had to carry out a temporary repair, so jacked it up in the street and put the old rubber ones (and the thick cable ties) back again.
Not pretty, but it will do for now :
Excellent customer service from Powerflex to be fair, I contacted them directly, sent them the photos, and they've sent me a pair of replacements.
I've actually decided on an alternative hangers though as I think the powerflex ones allow the exhaust to hang too low.
Managed to fit the new ones prior to a night shift on Saturday, so they got a good run out to test them. The good news? The exhaust hangs better by the mid box and the bushes have lasted longer than the powerflex ones!
The not so good news, it's still rubbing on the beam, so it's time to do the same trick at the back box. More bushes on order....
The worse news? A run down to Coventry to pick up a computer for a friend revealed an issue that will see the car off the road for a while....
I'm pretty sure the supercharger has an oil leak. It's not using a large amount, but it's splashing over most of the OS of the engine bay, including the belts. I need to get it off and post it to a specialist ASAP.
In annoying news. Some people are utter bellends. Someone has keyed the driver's door.
On the positive side again, I made it back from Coventry to York without the charger blowing up!
I've actually decided on an alternative hangers though as I think the powerflex ones allow the exhaust to hang too low.
Managed to fit the new ones prior to a night shift on Saturday, so they got a good run out to test them. The good news? The exhaust hangs better by the mid box and the bushes have lasted longer than the powerflex ones!
The not so good news, it's still rubbing on the beam, so it's time to do the same trick at the back box. More bushes on order....
The worse news? A run down to Coventry to pick up a computer for a friend revealed an issue that will see the car off the road for a while....
I'm pretty sure the supercharger has an oil leak. It's not using a large amount, but it's splashing over most of the OS of the engine bay, including the belts. I need to get it off and post it to a specialist ASAP.
In annoying news. Some people are utter bellends. Someone has keyed the driver's door.
On the positive side again, I made it back from Coventry to York without the charger blowing up!
Uggh how annoying. At least the supercharger can be rebuilt (JMR seem to have a good rep but I am sure there are others). Sorry to see the keying, hopefully that looks possible to wet sand (at worse) and polish - fingers crossed.
Is your car lowered? I found my stock exhuast cleared the beam but had a miltek fitted and that sometimes clangs against it. Mine is only lowered by 25mm on eibach springs. I've tried moving the exhaust around but am going to resort to a bodge - cable tie an old silicon hose to the beam or I might stick the stock springs back on it.
In other news for myself I've picked up another Corrado (2.0 16v to sit along side my VR6). Possibly having a midlife crisis as I've also picked up a 1 owner mk2 Golf GTI too! Have just updated my readers ride thread for photos
Is your car lowered? I found my stock exhuast cleared the beam but had a miltek fitted and that sometimes clangs against it. Mine is only lowered by 25mm on eibach springs. I've tried moving the exhaust around but am going to resort to a bodge - cable tie an old silicon hose to the beam or I might stick the stock springs back on it.
In other news for myself I've picked up another Corrado (2.0 16v to sit along side my VR6). Possibly having a midlife crisis as I've also picked up a 1 owner mk2 Golf GTI too! Have just updated my readers ride thread for photos
Edited by pfnsht on Monday 3rd August 18:52
@pfnsht apologies for the delay in replying, my time has been occupied fixing other people’s vehicles.... No it’s not lowered (at least I don’t think so) - the previous owner had it out back from slammed to standard just before I bought it.
I think the main problem may be the 16v exhaust that I fitted to it might have slightly different hangers. I’ll see if the new hangers for the back box make the difference when they turn up and I get round to fitting them!
@Spinakerr yes it’s rather unfortunate on both counts. However, not unexpected I suppose give the reputation of the G60! It’s been over five years since the last rebuild, and I was thinking about doing it anyway, this has just forced my hand slightly!
A few phone calls to various places (Stealth, JMR, OCD and Tempest RS) see JMR emerge as the favourites. They did the last rebuild, and while Troy from Tempest RS is a lot closer and definitely has the skills he’s moving more to motorsport rather than road cars. The car is rather sadly parked up under a cover until I can get the charger off (there’s a good guide on the forum) and post it down to them.
Right, back to fixing the accursed 207 for a friend....
I think the main problem may be the 16v exhaust that I fitted to it might have slightly different hangers. I’ll see if the new hangers for the back box make the difference when they turn up and I get round to fitting them!
@Spinakerr yes it’s rather unfortunate on both counts. However, not unexpected I suppose give the reputation of the G60! It’s been over five years since the last rebuild, and I was thinking about doing it anyway, this has just forced my hand slightly!
A few phone calls to various places (Stealth, JMR, OCD and Tempest RS) see JMR emerge as the favourites. They did the last rebuild, and while Troy from Tempest RS is a lot closer and definitely has the skills he’s moving more to motorsport rather than road cars. The car is rather sadly parked up under a cover until I can get the charger off (there’s a good guide on the forum) and post it down to them.
Right, back to fixing the accursed 207 for a friend....
The accursed 207 has been fixed and returned, I have the rest of the week off, the forecast is... OK. Let's be about it then:
There's an excellent guide on the Corrado Forum which I followed, and I don't intend to replicate, although there were a couple of things I discovered along the way....
Access to the charger is actually pretty good, even with the oil cooler added. Headlight and airbox off and no contortions were needed.
Definitely more oil mist on the inside of the outlet to the intercooler than seems healthy :
Access definitely made easier by not having the silencer box in the way. Hurrah for beautiful aftermarket parts! (Also nice to see the coffee machine gasket isn't the source of the problems...)
Tensioner off and all* bolts holding the charger in place removed.
(*not quite all, there are more than I saw in the guide. This caused half an hour of head scratching and frustration at the end of the process.)
You do need to remove the bracket attached to the front of the engine block. There are 4 no. 6mm hex bolts although only three are easily visible....
It helps to remove the dipstick and the plastic insert that sits in the dipstick tube. Then, when you've found the bolt you missed, the game of 3D Tetris can begin.
However, once you've completed rotating it on a number of orientations, you should have this in your hands :
... and this where it used to be :
It's now boxed up and awaiting collection by courier to take to JMR. For anyone interested in the internals, here are a couple of shots of the guts of it through the air intake showing how it actually works as a supercharger:
... and some random prettiness:
.
Managed to get it off and all tools packed away before the rain turned up too. Happy with that, although I've got to put it back again yet of course!
There's an excellent guide on the Corrado Forum which I followed, and I don't intend to replicate, although there were a couple of things I discovered along the way....
Access to the charger is actually pretty good, even with the oil cooler added. Headlight and airbox off and no contortions were needed.
Definitely more oil mist on the inside of the outlet to the intercooler than seems healthy :
Access definitely made easier by not having the silencer box in the way. Hurrah for beautiful aftermarket parts! (Also nice to see the coffee machine gasket isn't the source of the problems...)
Tensioner off and all* bolts holding the charger in place removed.
(*not quite all, there are more than I saw in the guide. This caused half an hour of head scratching and frustration at the end of the process.)
You do need to remove the bracket attached to the front of the engine block. There are 4 no. 6mm hex bolts although only three are easily visible....
It helps to remove the dipstick and the plastic insert that sits in the dipstick tube. Then, when you've found the bolt you missed, the game of 3D Tetris can begin.
However, once you've completed rotating it on a number of orientations, you should have this in your hands :
... and this where it used to be :
It's now boxed up and awaiting collection by courier to take to JMR. For anyone interested in the internals, here are a couple of shots of the guts of it through the air intake showing how it actually works as a supercharger:
... and some random prettiness:
.
Managed to get it off and all tools packed away before the rain turned up too. Happy with that, although I've got to put it back again yet of course!
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