tonedef

Cheers mate, might as well make it easy to get under there and do all those jobs…I need a step up to get under the bonnet!

Went for a bit of a drive this morning, home, washed and assumed the winter position (hopefully the coming spring will be a bit more normal than the last one was). Just about to declare SORN and writing the winter jobs list!

Might be worth dropping lilfuzzer a pm, he had a few headlinings for sale a couple of years ago, might have one left.

As easypops has said, the servo needs to be the one without the pedal position sensor, I bought a new one from onlinecarparts, VAG p/n was 358 612 107 B. I'm sure that given time I'd have picked one up from a breaker but I was in a hurry at the time and all those turning up on eBay seemed to be rusted within an inch of failing. A second reason that the existing servo can't be used is that the mounting studs for the master cylinder are at 45 degrees whereas those on the Teves 20 master cylinder are horizontal which is something of a deal breaker. I also had to source other parts as my original kit was from a Golf, the ABS dash lamp from the Passat 3AO 919 235 AF fits into the opening in the dash and you can install the Corrado lens to make it look original although the airbag lamp needed disabling as mine was permanently lit, the loom for it would also be useful although I couldn't find one and made my own, easypops was luckier and managed to pick one up! You'll also need the correct brake fluid reservoir if you're using Golf kit as the original will sit at a strange angle and rub on the inlet pipe, I used the non-ABS version from various models, part number 358 611 301. You'll also need to swap out the rear wheel speed sensors as the plugs on the existing ones don't match the loom, I bought a pair of 1H0 927 807 D as they had the longest cable on them (the Golf loom lands a bit short under the rear bench) although the sensor part itself seems to be a bit too long and rubbed on the sensor ring when I installed, I made some temporary spacers to cure this but will address it over the winter, I might make some up by cutting and soldering the two flavours together.

A few years back I bought a new headlining after getting a bit carried away cleaning mine and leaving it saggy in places. I looked at this thing sat in the garage for months, terrified of swapping it, thinking it was going to be the job of nightmares. I finally bit the bullet one day and set to fitting the new headliner...and an hour later it was finished, one of the easiest jobs ever faced! But as fendervg says above, you’ll not need any of that for the aerial base, remove a bit of trim and you’re looking at it!

See if you can find an alarm fitter has a Toad Ai606 in stock, you’ll not go wrong with that. It was the first job I had done on the VR over 20 years ago, and it still works fine!

I was just about to tell you BR for the 12V…I grounded at an earth stud in the tailgate. But as you suggest, 31 is always ground of course!

If you have any joy with this we need photos! This is one of my jobs this winter.

If you look at the following pinout for the OBD1 VR6 ECU you'll see these allocations: Pin 40 TPS signal 1 Green/White Pin 41 TPS Power Black/Grey Pin 33 Sensors Ground (including Throttle) Brown Click I also have a Golf wiring diagram which shows the same wiring,: TPS pin 1 to plug T42 pin 28 Brown/Green which joins a group of other Brown/(Second Colour) wires before becoming finally a brown which goes to ECU plug T68 pin 33 TPS Pin 2 to plug T42 pin 29 Green/White to ECU plug T68 pin 40 TPS pin 3 to plug T42 pin 34 Black/Grey to ECU plug T68 pin 41 Admittedly it's not a Corrado diagram but I've swapped enough looms around to know they generally follow, it suggests your wiring whilst maybe not the neatest is correct as installed.

Congratulations on the new motor!

You're very welcome, shame I don't always know my 5 from my 8 eh??? Check if one or both lamps are lit, mine lights up on the right side at start up/ABS check. The left lamp for the airbag warning was permanently lit until I snipped it off the PCB...that fixed it!

Glad to hear it’s up and running, it’s always nervy when you’ve carried out so much modification work, I know OBD2 and Teves20 are both well trodden paths but they’re still fairly major tasks. Looking forward to seeing the next steps!

As fendervg says, it’s really easy to remove the liner, no tools required. Tilt the sunroof, slide the liner backwards simply by pushing the frame and it come unclipped from the roof, slide it into the roof space and rotate 90 degrees until it will feed forwards and out. Just don’t force anything, the mechanism is made of what we always referred to as “monkey metal”, you don’t want to break any of the bits, trust me. I had to drill and tap one side of mine to fix it back together with an M3 countersink screw and locktite after getting too hasty one time!

It’s been a love/hate thing, filled with highs and lows!

Just realised that we’ve had the VR6 for twenty years and two days. Happy belated birthday!

I started mine regularly when it was at home but at the paint shop it was sat for the best part of two years. Another thing to look out for if the fuel has deteriorated to the point the pump has rusted in it is the injectors, when I came to get it started only two of them were actually firing, I had to have them serviced to clean out all the crud.

I must be almost driving past your house a couple of times a day at the moment Chris, staying in Hull and working at the terminal in Easington. How’s progress recently?

Mine did exactly the same when it was laid up in the paint shop for a couple of years. The pump was rusted solid and had to be replaced, I managed to get the sender working again with a bit of TLC though.

Great turnout there, nice to see some normality these days! Well done for arranging it.

Looking forward to seeing photos from today’s meet, was hoping to make one but have to start on site early tomorrow morning so have a busy day today at work getting ready for a 5am start. The client obviously hasn’t any concept of Bank Holidays! Looks like you’ll have the weather for it 👍

Thanks for the replies, and suggestions. It's definitely turning the engine over every time so the starter's engaging fine, it does sometimes seem to disengage as if the engine's spinning faster than the starter can keep up with, a second attempt will almost always start it when this happens. I'm sure it's OK electrically as it runs fine the rest of the time. It's always runs smooth and never seems to hesitate, probably aided by the OBD2 management, I forget what it was like before that. Tappet jacking definitely seems like it could be a consideration and of course there might be a sticking follower, I replaced them when I rebuilt the top end, that was fourteen years but only around 20,000 miles ago. I'm also running 268 cams so the followers have a bit more work to do than standard. I'll probably put an oil pump on this winter's list, can't hurt after 25 years can it although it's a shame to do the oil as that's only a few hundred miles old, good job I bought 25 litres of Synta!

It might seem I’m doing it the wrong way round but because of the recent wet weather I’ve been commuting on the motorbike rather than the Corrado as I’d rather the car stays clean and dry! This means that I start the car, drive it out of the garage get the bike out or in and put the car away, maybe five minutes tops running time twice a day. A few times it’s been really weird starting, it seems to spin over really quickly almost like the engine’s got no plugs in, then it splutters into life until it finally settles to running on all six after maybe 30 seconds or a minute. Other times it starts completely normally. I’d suspect a plug or injector if it wasn’t for the fast spinning, can the oil non-return valve between the block and the head allow head pressure to fall overnight which then needs to rebuild in the followers once it starts? Would that decompress the engine, it’s not clattering like they do after a long lay up? Going for a run today which might resolve it but just puzzled!

Congratulations, it’ll be like Happy New Car Day all over again!

1993 Aqua Blue VR6. If this is your car, I have the original dealer supplied service book from when it was sold in Aylesbury until a service at 165K miles in Boston Lincs in 2011. I bought the wallet on eBay for the owners handbook as mine was missing. DVLA shows the car as SORN since 2016 but that they issued a V5C in 2019 suggesting somebody may have bought it or maybe changed address then. Prove to me it’s your car and I’ll post you some of its history for free, can’t say fairer than that!

Mine was first registered by John Fox in Nottingham 01/11/95 but there’s a delivery date of 24/10/95 in the service book from Milton Keynes. It was then serviced by VAG dealers in Towcester, back to Nottingham, Birmingham, Norwich, back to Nottingham again before I went all the way to Surrey to buy it with 57K miles on the clock in September 2000.