ProdigalSon

Yesterday: Replaced clutch slave cylinder, re-bled system (no change :(), largely neglected our esteemed guest CazzaVR :oops: and started to remove the inlet manifold to get access to remove the clutch master cyl. Today: Removed the FPR to get the inlet manifold out (Allen bolt into the manifold through FPR bracket rounded off :bad-words:), removed the inlet and split the throttle body off so the manifold could be cleaned, removed old clutch master and fit a spare from the scrapper, fought with the hydraulic union, lost a master cyl nut down inside the steering column's rubber boot, and spilled a bit of brake fluid on the wing! :shock: Time to call it a night :roll:

Who? :?

Possibly, but I was thinking Shooter. Yes... somewhere.

True story. Will have to do it slow: slow is smooth, smooth is fast :wink:

The hard way: open nipple, push pedal, close nipple, pull pedal, repeat several times (thanks to the missus for being pedal monitor) :lol: At least it is guaranteed to stop air going back up the line... Will do a search to try to find what's involved in swapping out a slave - want to do it as fast and efficiently as possible. If that doesn't sort it, then I'll do the master as well (and it looks like that would be easier without the inlet manifold, so I may as well do my long delayed phenolic gasket also)! Thanks :wink:

And as if by magic... 8) Weird seeing our cars with 'old' styling :wink: The rolling shots didn't really work, but I have the means to do them properly now :D

:oops: Shamed into pulling out the other pics, and making them shine too :D Watch this space...

OK, so last night I ordered a new slave cylinder and VR6 clutch kit, to arrive in time for the weekend :wink: This evening I did a proper bleed, and ran about 500ml of fresh fluid through the hydraulic clutch line, bleeding at the slave end. However, every slug of fluid pushed out was full of bubbles, sometimes large, sometimes so small it was just froth :( So, given that it can't be the either of the bleed nipples sucking air back in, I'm thinking that it's either a) the master cylinder leaking air in and then forcing it down the line, or b) the slave cyl pulling air in and squirting it out as soon as fresh fluid comes down the line - dodgy seals in one of these perhaps? Is there any way I can tell which is broke without taking the engine bay apart? The car is due for it's respray on the 15th [Edit: and I will be away for 2 weeks from that time], and I am going to have limited time before then to get all that hydraulic stuff swapped over, and I don't want to postpone the bodywork just because it's not drivable... :cry: Help! :help:

Yes it is! :wink: :roll: :lol:

/\/\/\ You rule/rock/pwn!* (*delete as appropriate) :lol:

Oh right, like my mk2 was doing... :puppydogeyes: Yeah, but if you think about it, if the slave cyl is not pushing enough force onto the throw-out bearing due to mechanical/hydraulic 'failure', it would have the same effect as the throw-out bearing pushing/forcing its way between the broken halves of the diaphragm plate(?) as was happening on your Mk2, no? Same symptoms, different causes, possibly. Plenty to check out though, and good call on the 'split plate' front, it could yet be that :)

Thread resurrection/loose end tie up! First hand experience now shows that we had a dead ISV, if I recall correctly :roll: The ECU pulses the 12V power to the ISV to maintain idle, it varies the duration of the power (mark/space ratio or duty cycle) in order to regulate the idle speed by varying the amount of air that goes through the valve. Any ISV that does not pulse when connected to a known good loom is duff. :wink:

Welcome to the forum, and to Corrado ownership! :D Pretty sure that blue/white one is unused, and is usually tied back (I'm assuming yours is a 16V, no?) Yandards seems to be a bit of an ace with the 16V engines he certainly helped me and boost monkey hugely, do a quick search for valver wiring or see here: Click HTH :wink:

:shock: We want names! (and the URL) :lol:

Popped into the local dealers today to collect random bolt bits for boost monkey, and checked on clutch slave cylinder price - £55 inc. VAT inc. discount - does that sound a bit much? Thought someone said the new resin ones were around the £30-40 mark... Perhaps that was GSF or similar pattern part though. Supercharged, the current slave is the original cast part as far as I can see (although I haven't tried trawling through the previous owners' receipts to see if it has been changed). I wouldn't be too surprised if it's my bad bleed 'technik' that has let air in - when I had bled about 600ml of fluid through the clutch circuit and out of the slave cyl, I got a bit paranoid that there were still bubbles, and that the air was being sucked back down the threaded sides of the bleed nipple when the clutch pedal was pulled up, so I blobbed some LM grease around it to make it airtight! :lol: If I'm honest, I ran out of brake fluid before I was totally satisfied that all the air was out... When the car is in gear, it is a b!tch to get out again - really have to yank the gearstick - and vice versa. Putting the pedal down does very little at all. There's more grind than a Caribbean beach party :wink: Glad that I have a spare clutch master cylinder though :) Quicky question now that I have lots of intelligent readers - if I do need to replace the clutch (which will be the case eventually), can I just swap in the VR6 variant as replacement, or is it more complex than that? However, before any of that, I will do a proper bleed: open nipple, push pedal down, close nipple, pull pedal up, repeat etc. Once I have eliminated the fluid itself as cause, I will bite the bullet and go for a slave and/or master cyl swapout.

Does it have a "Dyson" badge anywhere? You might want to remove that... Seriously though, you have all the bits, no? You/we should work out when to do that. Away from the 16th March to 3rd April though, sorry :(

My fears were confirmed - although the early sunday morning :morning: gearstick alignment went very well, the clutch stopped disengaging, so I reckon it's a clutch slave or master cylinder failure :roll: Missed taking my C to the mini meet yesterday :( but took the opportunity to see and photo the others' cars :D Will bleed the clutch hydraulics very carefully once more before ordering a replacement slave cyl, to make sure it's not my bad technique :lol: and have discovered that we reclaimed a master cyl from the scrapper last weekend :) Watch this space... :wink:

Did see an SNS dyno plot a while ago, but can't find it right now :scratch: Anyone else?

I think the 'springs' are the apex springs that sit in the grooves inside the housing and scroller and hold the seal in the right place - from above they are curved to fit the spiral of the scroller, and the circle of where the two halves crack open, and from the side they have a shallow 'seesaw' shape, like this: /\/\/\/\/\/\/\/\/\/ They look more fragile than anything else and are very lightweight - you could think of them as being more like flexible spacers than conventional springs. I don't think you'll have any problems with them - just be gentle :wink:

Yes :) Er, will let you know after the Stealth r/r day in April :oops: My previous G60 had the same pulley (but not the SNS chip that I have now), and at the time it was allegedly 190bhp and 200lbft, although not verified... I'm keen to find out myself tbh.

Hey bro, Some rolling pics of your C in the dusk this evening - not the best quality, but OK for a first go I guess... Corrado92.pdf_DSC6088_filtered.jpg[/attachment:332yvi5o] passat climatronic wiring diags.pdf_DSC6096_filtered.jpg[/attachment:332yvi5o] climatronic wiring-Golf from May 01.pdf_DSC6097_filtered.jpg[/attachment:332yvi5o] 2.8l 24v Climatronic system.pdf_DSC6098_filtered.jpg[/attachment:332yvi5o] _DSC6107_filtered.jpg[/attachment:332yvi5o] And yes, it does look dark, almost black, no? 8)

After more discussion, sounds like new clutch slave cylinder (£30?), and if that doesn't sort it, swap out the master cylinder with the reclaimed unit from last weekend's scrapfest... Gear adjustment is dead easy when you get your head around it :D I had the same symptoms, which were sorted by the tweak - now if only I could get the clutch plates apart... :roll:

:shocked!: Sweet! Was hoping I'd missed something :wink: Hmm, so I think I'll buy the slave anyway and if that doesn't work, will swap out the master too. And we have the copper hydraulic lines off the breaker also... Glad to have a plan :D I hate having this kind of thing just hanging unresolved

8am - aligned gearbox cables as per stickied topic :D 9am - re-bled clutch master and slave cylinders :) Took a whole litre of fluid though :? 10am - clutch pedal works, but no engaging or disengaging of gears :( 1pm - put all the tools away and resigned myself to bumming a lift from boost monkey to the Oxford mini meet :cry: :roll: My first meet, and no C to take *sigh*

Thanks for quick replies guys :thumb right: Interesting - clutch is not making obvious 'noises', and not easy to tell if it's slipping in gear as I don't want to put it in gear for fear of not being able to get in to neutral again! But, reversing onto the drive was fun - I had to jam on the handbrake because with the clutch pedal down the car kept pulling backwards towards the house... Had to quickly turn ignition off and then release handbrake and rock the car to get reverse disengaged :roll: Hmm, yes there is some fluid below the slave cylinder, but it is most likely from Friday when the bleed pipe flew off the nipple under pressure allowing a big gulp of air back in :mad: So not exactly conclusive proof... :? Should clean that up and work the clutch a few times to see if it's weeping, I guess. We pulled a clutch master cylinder off the Corrado shell, and didn't you sell that already? Pretty sure there wasn't a slave cylinder as it is attached to the gearbox/clutch housing... or did I miss something? I read elsewhere that the new improved clutch slave cyl is made from resin(?), and is about £40 from VAG, so will get one of those. Will also look into a VR6 clutch, although might not do that before the gearbox is refurbed... Not booked a date for a 'box rebuild yet, but it's looking increasingly urgent! :lol: Priority is to get the car running, partly as it is a daily driver, but more importantly so I can keep my bodyshop appointment on the 15th!