Volkswagen Corrado G60
Discussion
I've had both 16 valve versions, the VR6 but never the G60, but I'd always fancied one after finding the VR6 too nose heavy for my tastes.
I found myself in the fortunate position to be able to pick one up, viewing it as a relatively depreciation-proof high days and holidays car.
I wanted one as standard as possible, as. I'm really not going to be using it very much for daily transport (I cycle) or for long distance workhorse duties (motorbike). There's no point in trying to get a tweaked one as it wont ever be as fast as the bike...
So...here is what I came up with:
The supercharger has no rebuild history, so that's top of the list. It also needs a headlight wiring loom, some earthing issues sorting on the clocks, the drivers seat bolster, the sunroof (if I can really be bothered...) and a few trim bits (if I can find them!).
There's a mysterious kangerooing issue that might be the clutch, throttle cable or injectors....but for now I can drive round it.
Time to see if my old Corrado Forum login still works....
Cheers,
Tom
I found myself in the fortunate position to be able to pick one up, viewing it as a relatively depreciation-proof high days and holidays car.
I wanted one as standard as possible, as. I'm really not going to be using it very much for daily transport (I cycle) or for long distance workhorse duties (motorbike). There's no point in trying to get a tweaked one as it wont ever be as fast as the bike...
So...here is what I came up with:
The supercharger has no rebuild history, so that's top of the list. It also needs a headlight wiring loom, some earthing issues sorting on the clocks, the drivers seat bolster, the sunroof (if I can really be bothered...) and a few trim bits (if I can find them!).
There's a mysterious kangerooing issue that might be the clutch, throttle cable or injectors....but for now I can drive round it.
Time to see if my old Corrado Forum login still works....
Cheers,
Tom
Edited by darkyoung1000 on Friday 23 February 06:42
Nice G60!
I had one too, great car and ooooh, that noise! My G60 grenaded itself on the M25 while cruising at 70mph, annoying as i had just serviced the engine and it was about to be sent to Jabbasport for a charger service. Turned out my Oil return hose into the sump was blocked. Luckily I was able to get another charger from Jabbasport for a bargain!
Kept mine standard for at least a year until i started to notice that when two up, i'd see a noticeable difference in performance so it wasn't long until I was down at G-werks having a SNS chip and pulley, RSR outlet and the boost return mod done.
I had one too, great car and ooooh, that noise! My G60 grenaded itself on the M25 while cruising at 70mph, annoying as i had just serviced the engine and it was about to be sent to Jabbasport for a charger service. Turned out my Oil return hose into the sump was blocked. Luckily I was able to get another charger from Jabbasport for a bargain!
Kept mine standard for at least a year until i started to notice that when two up, i'd see a noticeable difference in performance so it wasn't long until I was down at G-werks having a SNS chip and pulley, RSR outlet and the boost return mod done.
So...the list of niggles has started being written, and looked into. I always knew that she'd need some work despite being not a pure 'project' car.
Not that it's the most important but a set of Pioneer front speakers have been ordered to replace the blown ones.
There's a decent headlight loom upgrade on the way so I can actually enjoy driving at night too.
Having looked at the intermittent flickering needles (especially the rev counter) when warm, I investigated all of the earth points under the bonnet looking for an easy solution....but no improvement. Clocks out next then!
The strange kangerooing under partial throttle....not fixed but having taken the distributor cap off and found it far from perfect inside (the contacts were corroded) I have ordered a replacement after emery cloth and Wurth contact cleaner yielded no results. As Euro Car Parts had a sale on....I decided to go the whole hog and get a rotor arm, HT leads and plugs at the same time. £32 delivered....why not!
No time to fit them just yet, but here's crossing fingers. If not this, then it's back to the Bosch diagrams for their digifant system!
I'm going to need some new boost hoses too, the original rubber ones are showing signs of wear. Anyone any suggestions? Black please not blue and as OEM look as possible (although I like the idea of silicone)!
On the plus side...the handling is certainly sweeter than my old VR6, and she pulls well for an old girl, especially above 4k rpm....
Cheers,
Tom
Not that it's the most important but a set of Pioneer front speakers have been ordered to replace the blown ones.
There's a decent headlight loom upgrade on the way so I can actually enjoy driving at night too.
Having looked at the intermittent flickering needles (especially the rev counter) when warm, I investigated all of the earth points under the bonnet looking for an easy solution....but no improvement. Clocks out next then!
The strange kangerooing under partial throttle....not fixed but having taken the distributor cap off and found it far from perfect inside (the contacts were corroded) I have ordered a replacement after emery cloth and Wurth contact cleaner yielded no results. As Euro Car Parts had a sale on....I decided to go the whole hog and get a rotor arm, HT leads and plugs at the same time. £32 delivered....why not!
No time to fit them just yet, but here's crossing fingers. If not this, then it's back to the Bosch diagrams for their digifant system!
I'm going to need some new boost hoses too, the original rubber ones are showing signs of wear. Anyone any suggestions? Black please not blue and as OEM look as possible (although I like the idea of silicone)!
On the plus side...the handling is certainly sweeter than my old VR6, and she pulls well for an old girl, especially above 4k rpm....
Cheers,
Tom
Samco do a replacement black OEM-style hose set for the Golf G60/Rallye but I don't know whether it includes the supercharger and intercooler hoses. It's also listed as LHD only
Venair do a Corrado-specific full set inc. boost pipework in a range of colours, including black, but they're expensive (~£200).
Venair do a Corrado-specific full set inc. boost pipework in a range of colours, including black, but they're expensive (~£200).
The car is now in John and Troy's hands at JMR, with the supercharger nearly out for a spot of fettling.
They mentioned that it seemed pleasingly standard bar a couple of minor additions...and confirmed that Euro Car Parts had indeed sold me the wrong oil filter....to go with the wrong spark plugs.
These minor issues aside, I intend to come away with a fettled charger, and a new set of clocks, as it's likely that the Printed Circiuit Board at the back of the existing ones is the source of my trouble.
The fettling continues, although I'm happy with how it's performed so far...
Cheers,
Tom
They mentioned that it seemed pleasingly standard bar a couple of minor additions...and confirmed that Euro Car Parts had indeed sold me the wrong oil filter....to go with the wrong spark plugs.
These minor issues aside, I intend to come away with a fettled charger, and a new set of clocks, as it's likely that the Printed Circiuit Board at the back of the existing ones is the source of my trouble.
The fettling continues, although I'm happy with how it's performed so far...
Cheers,
Tom
Thanks Andy, much appreciated. Troy has a set which I'm probably going to pick up, but if he can't find them, I'll drop you a line....
The good news is that the engine and charger are in rude health. The same cannot be said for the clutch line, rake lines, front subframe and a number of other things!
You are quite correct, the car is in safe hands and John really knows his stuff.
Cheers,
Tom
The good news is that the engine and charger are in rude health. The same cannot be said for the clutch line, rake lines, front subframe and a number of other things!
You are quite correct, the car is in safe hands and John really knows his stuff.
Cheers,
Tom
Neil G60 said:
Good to see JMR are getting involved in salvaging another G60, Andy and I have known John for donkey's years. Guarantee you'll drive your car out there with a smile on your face (and a stage 4 port, external oil cooler, new rear beam bushes, replacement heater matrix, coilovers etc) 
Well you were right about the stage 4 port, and the external oil cooler and rear beam bushes are on the 'to do' list. However, these took second place behind what was found on the day:New injectors and wiring harness
New knock sensor
Various bits of tubing under the bonnet
New rear brake lines and connectors
New fuel filter and plugs
New front subframe and wishbones
Ouch.
The car still has some issues (sluge in the fuel tank means when it's low it stutters round corners - needs draining) and a possible temp sensor (the blue one) is required. Also I need to fit the replacement clocks, new ignition switch (just in case) and a few other things...
Still, here's some pictures
On the operating table
Awaiting parts
Newly powder coated subframe
Installation of the above.
Needs sorting by the summer or she's going to get really warm...
Cheers,
Tom
I think my last post mentioned sludge in the fuel tank making it stutter around corners, well, since getting back from JMR in January, I hadn't really driven it much, I was trying to get the fuel level as low as possibly, so I could drain the tank and remove the sludge, filter and then refill. This even resulted in getting almost stranded by parking on a slope, but anyway, I digress....
Nothing in life is ever simple.
The good news is that the bottom of the fuel tank was clean! No sludge, no sediment, in fact, nothing that could really be causing the stuttering under acceleration and cornering.
The bad news? Taking the fuel pump out to have a look at it revealed the following:
Hmmm...let's take a closer look....
Bugger. It appears that not only the top and bottom diaphragms holding the pump in the body have been degraded over time (possibly with the help of ethanol in the petrol), but that also the rubbers mounting the pump in the body were knackered. My suspicion is that this was allowing the pump to move around inside the body and causing fuel starvation. Time for a new pump....
Yes....nothing in life is ever simple.
The early G60s had a two pump external system....ok, well it's not one of those, so I just need a 4 bar pump and sender.
The 4 bar pump and sender system made by Pierburg isn't made any more, so I need to find a 4 bar VDO pump, similar to that used in the VR6. Similar but with one important difference, the VR6 pump was 3 bar. Blast.
Every part number that I crossed checked, VDO, Pierburg and Bosch yielded a 3 bar pump only. I even got a pump and sender unit from Pierburg as New Old Stock from Andrew Page whic turned out to be 3 bar and had to be returned. Long conversations with various motor factors drew blanks, and even VW couldnt source even a 3 bar pump. A second hand unit on eBay was £100 with no guarantee that it wouldn't be suffering from the same problem....
However, persistent eBay searching yielded results from Germany for a 3-4 bar (apparently they come as either, but this one is a 4 bar) VDO style aftermarket pump from the JP Group (part number 1115202700 replaces VW part 1H0919651Q listed in ETKA as 4 bar). Result! £40 from eBay.
A compatible sender from VW then....nope, they no longer stock them....anywhere in the UK. The kind chap at JCT600 printed me off the ETKA page, so I went back to eBay an found a compatible one in Italy for around £80.
Now to try and butcher the carcass of the old one to make a working pump. This requires small audio style connectors for the sender unit, and fuel hose clips of various sizes - 10-12mm for the tank bypass, 14mm for the external lines from the top of the pump unit, and 15-17mm for the internal connectors to the pump itself. The butchering is relatively simple, line off - line on (making sure inlet and outlet are correct), wiring for the pump is only 2 wires which are push fit spade connectors, and then the sender unit needs connecting up (polarity not important)
With the newly created Frankenstein's monster of a fuel pump (a VDO body with the head of a Pierburg), it's just a matter of refitting.... Having previously syphoned out as much of the remnants of the tank as I could and let the rest evaporate, installing was relatively simple. Manouver into the tank, feel for the ring into which it locates and turn clockwise to secure it. Then push the Pierburg outlet cover back into the fuel tank aperture (it really doesn't want to go), scew back in the castellated plastic ring, reattach the fuel lines and loom connection, pour in syphoned out fuel, turn the key multiple times to prime, cross fingers and.... Hurrah!
The Corrado lives again! A short test drive with some hard acceleration and cornering seems to suggest that my fuel pump woes are over for now. The to do list is still a long one, but at least it's running again! As I've been using a ZZR1100 for most of last week, It doesn't feel fast, but then that's hardly surprising
Cheers,
Tom
The
Nothing in life is ever simple.
The good news is that the bottom of the fuel tank was clean! No sludge, no sediment, in fact, nothing that could really be causing the stuttering under acceleration and cornering.
The bad news? Taking the fuel pump out to have a look at it revealed the following:
Hmmm...let's take a closer look....
Bugger. It appears that not only the top and bottom diaphragms holding the pump in the body have been degraded over time (possibly with the help of ethanol in the petrol), but that also the rubbers mounting the pump in the body were knackered. My suspicion is that this was allowing the pump to move around inside the body and causing fuel starvation. Time for a new pump....
Yes....nothing in life is ever simple.
The early G60s had a two pump external system....ok, well it's not one of those, so I just need a 4 bar pump and sender.
The 4 bar pump and sender system made by Pierburg isn't made any more, so I need to find a 4 bar VDO pump, similar to that used in the VR6. Similar but with one important difference, the VR6 pump was 3 bar. Blast.
Every part number that I crossed checked, VDO, Pierburg and Bosch yielded a 3 bar pump only. I even got a pump and sender unit from Pierburg as New Old Stock from Andrew Page whic turned out to be 3 bar and had to be returned. Long conversations with various motor factors drew blanks, and even VW couldnt source even a 3 bar pump. A second hand unit on eBay was £100 with no guarantee that it wouldn't be suffering from the same problem....
However, persistent eBay searching yielded results from Germany for a 3-4 bar (apparently they come as either, but this one is a 4 bar) VDO style aftermarket pump from the JP Group (part number 1115202700 replaces VW part 1H0919651Q listed in ETKA as 4 bar). Result! £40 from eBay.
A compatible sender from VW then....nope, they no longer stock them....anywhere in the UK. The kind chap at JCT600 printed me off the ETKA page, so I went back to eBay an found a compatible one in Italy for around £80.
Now to try and butcher the carcass of the old one to make a working pump. This requires small audio style connectors for the sender unit, and fuel hose clips of various sizes - 10-12mm for the tank bypass, 14mm for the external lines from the top of the pump unit, and 15-17mm for the internal connectors to the pump itself. The butchering is relatively simple, line off - line on (making sure inlet and outlet are correct), wiring for the pump is only 2 wires which are push fit spade connectors, and then the sender unit needs connecting up (polarity not important)
With the newly created Frankenstein's monster of a fuel pump (a VDO body with the head of a Pierburg), it's just a matter of refitting.... Having previously syphoned out as much of the remnants of the tank as I could and let the rest evaporate, installing was relatively simple. Manouver into the tank, feel for the ring into which it locates and turn clockwise to secure it. Then push the Pierburg outlet cover back into the fuel tank aperture (it really doesn't want to go), scew back in the castellated plastic ring, reattach the fuel lines and loom connection, pour in syphoned out fuel, turn the key multiple times to prime, cross fingers and.... Hurrah!
The Corrado lives again! A short test drive with some hard acceleration and cornering seems to suggest that my fuel pump woes are over for now. The to do list is still a long one, but at least it's running again! As I've been using a ZZR1100 for most of last week, It doesn't feel fast, but then that's hardly surprising
Cheers,
Tom
The
Edited by darkyoung1000 on Saturday 4th April 20:15
Good work on the fuel pump, I wasn't aware they are so hard to get hold of.
I also have both Vr6 and G60, the G60 is the weekend/show car.
I've also heard very good things about JMR and will be sending my charger for a stage 4 rebuild over winter. have you got a boost gauge or have you used the mfa to calculate the charger efficiency? a healthy standard charger should make 6-8psi on a standard size pulley
I also have both Vr6 and G60, the G60 is the weekend/show car.
I've also heard very good things about JMR and will be sending my charger for a stage 4 rebuild over winter. have you got a boost gauge or have you used the mfa to calculate the charger efficiency? a healthy standard charger should make 6-8psi on a standard size pulley
No boost gauge in the car unfortunately, so I used the MFA to give a reading - the output was healthy but as I had no rebuild history, I went for the safe option and got some minor porting work done at JMR at the same time.
An expensive trip, but one that probably saved me grief in the long run....
Looking forward to the Malton breakfast meet tomorrow, it's been a while since I've been there on 4 wheels!
Cheers,
Tom
An expensive trip, but one that probably saved me grief in the long run....
Looking forward to the Malton breakfast meet tomorrow, it's been a while since I've been there on 4 wheels!
Cheers,
Tom
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