G60'rado

So it's been a while again. But the project continues. Notched the front frame to fit the mkiv pendulum mount in. Then filled it in with 1/8" square stock, and plate. I should get a picture of the finished area. Probably the strongest part of the car. This is also the point I exceeded the capacity of the much loved 110v welder. I bought a 220v MIG/DC TIG that has been kicking ass. Engine hung on 2 VR6 mounts, and the one pendulum mount. Alot of work, but it means I can clear any turbo I want with out hitting the rear engine support. Still a little to finish, filling in the hole in the wheel well. Time to practice the DC TIG. Another big job under way, laying out the various harnesses, car chassis, and engine. And that is were we sit now.. One wire at a time.

Yup, I know what your talking about. I've got one more pass to do on just the passat wiring diagram before I'm happy with it. I've found there are even tie ins to the wiper motor, windshield wash button, rear defrost switch. Plus 2 Idle up connections to the motronic (one for AC, and one for rear defrost.) From there, it will be the interconnect with the corrado loom. Cheers, Joe

I'll be happy to share the info on the climatronic. The one caveat is the there are significant differences in years. I will be eventually posting a PDF of the wiring interconnect once I have the wiring diagram figured out, but it will be for a 2002 passat system. I'm not sure how that compares with a mkiv climatronic. Converting the current flow diagrams to an interconnect is proving a challenge.

Sounds like we are travelling down the same path. Building an early 2000 corrado TDI. I'm curious how you fit your passat cluster in. I haven't even started down that path yet, but it is coming up pretty quick. Cheers!

So I've been heavy into the electrical stuff. Building wiring interconnect diagrams for the ECU, Climatronic, Passat Cluster, and ABS systems. Plus figuring out how to reconnect everything from the 94 harness. I've lost a number of labels, but I think I'm 90% complete. I needed a break from wiring, so I decided to drop my engine engine for a fit test. Looks like I have to notch the frame rail a bit to fit the pendulum engine mount. Nothing some 1/8th bar stock can't reenforce. I do plan on running an uprated PD130 turbo in this thing eventually, so I need all the space I can around the back side. I may even completely remove the rear engine mount.

Work progresses on the ABS/EDL installation. Ran the 2000 jetta lines from the passenger side, modded up a custom bracket for the controller/pump, and built a harness that connects to the existing 94 corrado harness. A few more wires to connect the corrado abs wires to the controller. That will leave just the can bus, data link, and instrument cluster indicators. I've also been drawing schematics that shows the interconnects. The other project I've been integrating is the climatronic unit. This one will require a schematic, the system is pretty complicated. It doesn't help that I have a couple power wires I can't find in the drawings. The units I have are from 2002 2.8L / 2003 W8 passats. T16a/7 does to fuse 16. I just can't find what fuse 16 does. Full time, Run, Start+run? T16a/9 I think is run only (load reduction relay). *** So after much poking around in elsawin.. t16a/7 is hot all the time t16a/9 is hot on run and start..

It's been a while since I last did anything on the car. The last couple weekends were spend cleaning and sorting the garage. I put up 4 sets of shelves to organize my crap, including piles and piles of Corrado bits. Yesterday, I finished assembling my DE brake set from an '03 GTI, and installing them into the car. The calipers have been blasted, and baked with VHT silver. New boots, pins, and seals. de brakes

Climatronic modd'd box is in place, and I've started hooking up the electrical system again. I marked most of the wires before I pulled them, so it hasn't been too bad. A few markers have fallen off or got mangled, so I have some reading to do. Biggest whoops so far, I reversed the rear speakers, and had the loom backwards. So I had to take the back carpet out to fix that. But it sorted out 8 mystery plugs. I've started grafting in the climatronic into the stock harness. A simpler system to learn to follow the VW diagrams. After that, strip out the old ECU wiring, and connect the front half of the chassis wiring back into the fuse box.

Posted: Wed Jul 15, 2015 3:02 pm Some new parts have arrived. I got a full FIS cluster from a '02 W8 Passat, for $100 from a US wreckers. Lots of people have flashed the Golf/Jetta 1J0 code on them. As well, some BMW E30 wiper arms. Rumor has it they are direct bolt on, and work far better than the VW 'rado arms. Time will tell. I found an 02 vr6 Passat at picknpull with a full climatronic on it.. Got the heater box, the harness,and the head for $50. It was a little different, the the harness was integrated into the chassis harness, and not standalone. So I had to extract the wiring. Now I just need a mkiv standard heater box (the passat is completely different). I had one from the scrapped Jetta, but I binned it :| ------------------------------------------- Posted: Mon Jul 27, 2015 6:09 pm Worked on the car again this weekend. Puzzling out the climatronic system, and trying to adapt it to the existing heater box. The MKIV box didn't pan out, but donated some bits to the cause. Setup an old version of ELSAWIN so I could get readable wiring diagrams for the 02 passat system. Figured out most of the wiring, except for one wire that goes to the ECU someplace, that isn't on the prints. Powered it up, can move most of the motors, and swing the various doors. The recirc door has been the biggest hassle, mounting the motor is going to be a treat. I did get a different style motor from an AUDI A6, that I will try out. I have about 5 faults that I need to clear up. Ie Canbus, AC pressure sensor, and 3 positioner faults (motors aren't fixed down yet) If the franken-box doesn't work or is unreliable, I'm going to try adding mounts to the audi climatronic box to make it bolt up to the corrado. I'll likely do a how to, Climatronic - The hard way. It's been a good introduction to the VW current flow diagram, as opposed to the north american style wiring diagram that I'm used to. Then I went junkyarding.. The AUDI A4 (1997- 2003?) uses the same heater box, so I ripped out a spare, with motors. A just in Passat W8 (never seen one before at the yard) was dumped, so I stripped off a few sensors for the climatronic that were missing on the GLX i got the system from in the first place. Plus a spare head for the climatronic, and another full FIS instrument cluster (the US one will become a spare/parts). ------------------------------------------- Posted: Tue Aug 04, 2015 5:43 pm I've been working at adapting the climatronic to the stock corrado box. Finally figured out the connection for the recirc / fresh flap, using the A6 motor I salvaged last weekend. I get consistant travel without binding on both the recirc and defrost flaps. Lastly will be finish the 2 big flaps, temperature / and face/feet. Also managed to connect/hotwire the system up to my chinese KKL vagcom cable, and do a calibrate on the flap motors using the K-Line diagnostics. I will be looking at registering vagcom lite, and see if it does what I need.

Thanks for the kind comments. It will be a neat custom when finished. I like doing fabrication and electrical. A 2003 corrado, if vw had ever decided to build them.

Started connecting up the VR6 wiring into my G60, and splicing in the Passat Climatronic wiring. Spagetti!!

Test fitting wiring, and the TEVES 20 ABS Controller. Pulled out the old TEVES 2 harness, what a rats nest. Figured out most of the TEVES 20 wiring, and what needs to be spliced into the the CE2. Spent yesterday cutting up the MKIV ABS bracket and fabricating a custom one fitted to the car. I wanted to mock everything up to make sure all the custom stuff was going to fit.

Spent the week roughing in the wiring for the under hood area. Pulled out the old TEVES 2 harness, what a rats nest. Figured out most of the TEVES 20 wiring, and what needs to be spliced into the the CE2. Spent yesterday cutting up the ABS bracket and fabricating a custom one fitted to the car. I wanted to mock everything up to make sure all the custom stuff was going to fit.

Picture time! VR6 Rear swing arm. Jetta brakes & lines, new rotors & pads. Dropping the nasty g60 k-frame. VR6 k-frame and a few cleaned up suspension bits all spiffy. Suspension all assembled.. Brembo rotors, Neuspeed lowering springs. New tie rods, wheel bearings, VR6 monroe struts and VR6 strut tops, new control arm bushings, cleaned up VR6 swaybar, Girling 54 calipers. And how it sits today.. VR6 shifter, new motor mounts, CV shafts, Jetta heat shield.. Wiring is still coming out of the VR6, one bit at a time.

Posted: Wed Jun 10, 2015 10:15 pm G60 suspension is gone.. VR6 K-Frame is in, with a cleaned up steering rack, new boots, and new tierod ends. The cleaned up sway bar, wishbones, and steering knuckles are all installed. As well as a mk3 TDI hydraulic engine mount, and corrado vr6 transmission mounts. VR6 shifter box has been swapped over. Assembled the struts with my lowering springs. Made an adapter plate out of the old g60 spring perch to take the wider g60 spring top. Blasted my Girling 54s, and painted them with VHT silver. I was planning to use the Mk 4 front calipers, but they are a completely different animal. New Brembo rotors, and Honeywell pads. I've read that any front calipers but the mk 4 2.0 (and TDI) should work, so I might go shopping at PnP, and see what I can scare up, so I'm using all mk 4 brake parts. Everything torqued to spec. Also managed to fit the mk 4 TDI firewall heat shield. Next up, start transfering the last of the wiring out of the vr6, and the tdi wiring.