RW1

So they didn't put the relays back into position when the relay/fuse plate was changed :) Interference - Clutching at straws with the wiring picking up interference. Carries only 12 volt on/off signals or current supply 12 volts. Not likely. Those fault codes point to an internal valve block problem if its not the connections. .

Oooops. Keeps your spirits up mate. You'll mend. C.

Not sure as I picked it up at £1 at a show. 1 Litre tins. Expect £25 - £30. http://the-corrado.net/showthread.php?56822-Underbody-stonechip-guard&highlight=D003500 Brush it on with a paint brush. It self settles and will drip if applied too thick. .

The genuine VW underseal D003500 on the Corrado doesn't need hardener, just time to dry. Its PVC and skins fairly quickly (3 - 4 hours) so you can apply car body paint colour by spraying fairly quickly as per factory. It may take a few weeks to fully set under the skin though. The car (daily) is back on the road within half a day. .

Ugh! The wiper motor cover just slips on from the left side in a second. Thermostat cover... There's a technique of slipping in from the left side pointing down at 40' angle and turning it to horizontal as you feed it in. .

Velcro pads, fluffy side ones fitted. Anti-squeek film tape protection pads. Still to finish off with more neatly shaped ones now the prototype shapes are known. Got too cold last week in the garage to do the final cut ones. When they both contact, the cover rotates into a level position as shown. But no damage to the paintwork on the underside of the bonnet. Moved the wiper loom a little by re-curving it as front left corner of the cover was causing a foul. The cover itself... nothing other than to remove the silly foam strips VW supplier had put on. ---------- Post added at 1:19 PM ---------- Previous post was at 1:16 PM ---------- Passat part - 3A2 955 128, £7.49 + VAT. .

:lol: Have you been talking to Chris & Dave recently??? S'funny, done in the last 10 days... hmmmm, gonna have to keep an eye on those two. Fitted with "proper" adjustment modification. Get those scabs off! [ATTACH=CONFIG]53493[/ATTACH] Only thing is, the part rubs the underside of the bonnet as it settles, so you haven't finished yet! I bet they didn't sell you these ...... [ATTACH=CONFIG]53505[/ATTACH] ----------------------------------------------------- Update 26/02/12: Cleaned up the film shapes. [ATTACH=CONFIG]53509[/ATTACH] .

Inner Track Rod Ball Joint There are "special tools" for the trackrod inner ball joints. Need VAG1332 + VAG1332/6 or similar. [ATTACH=CONFIG]52729[/ATTACH] [ATTACH=CONFIG]52733[/ATTACH] Rack done off the car. .................................. Rack Adjuster The tool specified for RHDrive "TRW" Steering Rack and LHDrive "ZF" Steering Rack use is a VW524 special tool. [ATTACH=CONFIG]52737[/ATTACH] Rack Adjuster adjustment is same for both TRW & ZF type racks as Kevin has already written. .

There is usaually a lock nut on the adjuster to undo. It may take out centre area play but the ends of the rack will cause stiffer steering as they won't be worn. .

There were front bumper changes, but iirc, they are cosmetic only and shouldn't affect the fitment of the later wings. .

Pump doesn't run unless the ABS detects a need to. Doesn't usually affect the pedal on start up either. Brakes remain in a latent state, ie. all ABS valves in the ABS block relaxed and the pump off, no pump unless the wheel sensors detect a rotation speed change relative to each other. If you want to know its working. Find a wet surface and brake hard. The pedal will pump then. .

RHD only parts below: 358 721 401 Clutch Master Cylinder: --->> to 50-N-035 000 (Upto July 1992) 358 721 401B Clutch Master cylinder: from 50-P-000 001 --->> (August 1992 onwards) 358 721 388 Clutch Master cylinder: from 50-P-001 307 --->> (mid August 1992 onwards) .

I would tend not to break down the fuel metering head for three reasons (at least). 1) Some parts, particularly the central fuel control plunger is a very tight tolerance, iirc no seals. 2) Any spec of dirt left in the internals could cause problems. And may travel down to partially block the injector(s). 3) The fuel injectors are not really tolerant of small particles in the system (even the fuel filter can let through dirt that will clog the injectors) unlike later/more modern injectors which fully open and time injection of fuel. K-Jet injectors are open all the time and work with a small or large openings. When open only a little, this is when the ijector blocks and dirt becomes embedded in the seal at the tip which then leads to distorted fuel injection spray and dribble leaking when the engine is turned off. Remember, you are in the part of the system where they are no protective fuel filters in the fuel path. Fuel has already passed through the fuel filter, so is assumed to be clean. There is a kit of parts for the pressure regulation side of things for the head. But this has to be set up with fuel pressure equipment as getting it at the wrong system pressure affects the fuelling in the K-Jet. The pressure regulation is shimmed. The kit is 035 198 685 - parts kit for fuel metering valve. If it ain't bust, don't break it down. Clean it up cosmetically with all connections coupled to keep out dirt and leave. .

Lets hope that bottoms it :) For the record, these are the ABS & EDL relays and their position on the Passat. Puzzling yours is different. [ATTACH=CONFIG]51961[/ATTACH] .

1H0 959 481B Not cheap at VW circa £30 Assuming yours a a 50RK000001 onwards chassis. Electrical section on ETKA, Electric Fan illustration, Item 9 .

If you are searching by part number in ETKA, its N"space""space"90316802 If you are looking at illustrations, its on the 3 way sensor housing showing the temp sensors, item 9. Yes domed as thay sit against the sensor's lip. The O rings are round, ie. the rubber is round, as well as the ring. It squashes into shape through heat & time. When I took mine out last October, they were still round in profile as per the new ones I got. .

I'd expect them to be up above the fuse relay plate by the bottom corner of the A pillar/windscreen corner. Words from the Passat 1994 VW manual are "Above the relay plate" for all three relays. So even look inside the dash inside lip behind the lights switch. If the valve is faulty ie wiring to it or the actuating coil is open circuit, it may be causing hydraulic pressure problems. And hence why the pump is seeing pressure problems with 01276 fault code. .

Yes they are, part N 903 168 02, £1.03 + VAT last October. And they are round in profile, not square. .

Yes they do, recognised by 6 hydraulic outlets for EDL enhanced, not 4, on the valve block. Not an EDL problem! 00276 = internal Valve Block problem with rear left ABS valve. 01276 = ABS relay (one with 5 wire conections [3 of which could be dual into the base pin, same colour] to the base) or the ABS pump or the ABS pump sender inside the pump. Also, really clean the ABS electrical connector pins/sockets to remove any dirt. Use WD40. .

If they are working, a frosty bonnet will show them up as they melt the frost. They also feel warm when heating. They never switch off when the ignition is switched on. Fuse 14, 10 amps. Sadly if the originals, they are long gone. It was/is a poor design inside. The windscreen wash easily leaks into the electrical part and soon corrodes the two contact discs that generate the heating. Have fan jets on the new daily. Not really impressed with them. Seem to be more easily deflected when driving at higher speeds above 50 mph so nothing goes towards the top of the windscreen. .

Resistor is 0.66 ohms, +/- 5%. Upper permitted resistance from the connection plug by the ABS motor is 2 ohms. Relays (3 off) are above the fuse relay plate. One is the EDL, it is the only relay of the three with 4 wires, the other 2 have 5 wires for one relay, 6 wires for the other relay to the base mounting. (Double brown counts as one) Fault codes??? .

I will have a hunt round for the resistor value. It will be low in value being wire wound and its size. Its in series with the pump motor when engaged by a relay. Would help if you stated which fault codes you seeing. .

What pressure setting is the pressure switch in the sender? Its usually stamped on the sender unit body like the pressure switch you took out About 0.5bar normally. It may be that this pressure switch is faulty in the new sender and is contacting even though the idle pressure is 2 bar. .

The big resistor is not directly the ABS. Its part of the Electronic Diff Lock (EDL) or Traction Control System (TCS) as VW UK decided to rename the function. The resistor is a drop down voltage resistance to run the ABS motor at a slower speed and therefore lower hydraulic pressure when EDL is engaged due to a wheel spinning/slipping when intially driving off upto 25mph approx. If the resistor is fitted, then the ABS valve block has two additional valve ports (totalling 6 instead of 4). The additional two valves are in the dual circuits going the rear brake pipes/brakes to cut off hydraulic pressure to them when EDL operates. That then allows the EDL to use the front ABS valves to control the two front wheels hydraulic brake circuits individually with use of hydraulic pressure the ABS pump provides. Nothing happens unless one or both the two front ABS sensors detect a wheel is slipping. At the occurrance, the slipping wheel is braked (not locked) by the slow running pump pressure forcing the drive to be taken up by the other wheel through the gearbox's mechanical differential. When it detects the wheel is gripping again, the ABS valve block releases the brake pad pressure to allow the wheel to drive again. After starting to move, at 25mph the EDL becomes inhibited by the ABS ECU. It also doesn't really operate unless the steering wheel is set between 10'o clock and 2'o clock. Outside these boundaries either side, wheel spin still occurs. If the connections become poor for the resistor, the EDL will have no hydraulic pressure to work with, as the pump won't be spinning. Some resistance means a slower running pump and less pressure than normally available. So the ABS ECU may operate the ABS valve block valves, but the front brake pads will not grip the brake discs enough to make EDL work efficiently. The resistor being higher resistance through bad connections will not stop the braking ABS circuits working properly. That voltage to the ABS pump is fed via a separate circuit path. .

Sockets doesn't mean you have digital engine ECU. They are just the digital hook up points if fitted and what is wired to them from which ECU. All four pins of the black and white sockets must be wired. So you must have 4 wires under the gear stick cover going to these two sockets. Two from the ABS, two from the Engine. If its one, two or three wires to this area, then the engine ECU isn't present digitally. The blue socket is not used. USA Corrado's have a MIL light in the dash that flashes the codes in blocks of 4 flashes. This is not wired on European & UK market Corrados and there is no alternative. . ---------- Post added at 10:12 PM ---------- Previous post was at 09:33 PM ---------- Corrado was built last week of March 1992. .