ProdigalSon

Having owned a rather lovely Aqua Pearl Blue '91 G60 a few years ago, when my Audi 80 was written off in May, my good mate CazzaVR didn't have to twist my arm much to get me to look at buying another Corrado... Needless to say I have now bought a 'stock' G60 in apparently very decent condition :D from a very nice chap near Cirencester about a week ago, after looking at a few examples It is a '92 K-reg (late exterior) in Satin Silver, with ABS and black leather electric Recaros 8) It is totally stock except for the fog lights, which have been removed and neatly blanked with mesh as the previous owner lived in the country and they kept getting chipped and smashed(!) and the wipers, which I upgraded to Lupo/aero wipers on Friday :) "I can see"! However, the engine has done nearly 170k miles, with a single charger rebuild at 85k, so I'm off to G-Werks tomorrow morning for a charger overhaul, a stand-alone oil supply for it, advice, and maybe some other nice bits too! My immediate wish list includes a set of coilovers so it doesn't look quite so much like a 4x4 :lol: a 68mm pulley and chip (SNS/G-Werks), and perhaps an oil cooler and/or chargecooler for good measure... My old G60 had some kind of US tuner chip to go with its 68mm pulley (never found out which one), so the current drive feels a bit weak in comparison :( ... Not for long though :D Here are some pics, taken after a good old clean today :wink: DSC4581.jpg[/attachment:3b60b] ETKA Corrado.pdfDSC4582.jpg[/attachment:3b60b] stromlaufplan_gamma4.pdfDSC4584.jpg[/attachment:3b60b] Corrado92.pdfDSC4586.jpg[/attachment:3b60b] 2.8l 24v Climatronic system.pdfDSC4590.jpg[/attachment:3b60b] passat climatronic wiring diags.pdfDSC4594.jpg[/attachment:3b60b] climatronic wiring-Golf from May 01.pdfDSC4598.jpg[/attachment:3b60b] UPDATE: Maybe the ABS won't be working for much longer... :( Drove home through some drizzle and puddles and the ABS warning light suddenly came on :shock: But if I turn off and restart the engine, the ABS light goes out, then comes back on a while later - ABS does work when the light is off, but doesn't even try to work when the light is on... Also noticed a clicking noise from the ABS unit in the engine bay, which was causing brake line pressure to modulate on the rear left wheel (could feel it with a finger on that line) - a dodgy sensor there perhaps? Any ideas? Will run it by the G-Werks guys, but hope it's not the pump as it's mega£££ if I recall correctly. Anyone with 2x2 VAG Com capabilities in the Oxford area?

Cool :) Do you have the bolts/screws as well? And how much do you want for them?

Hi Toad, Have these been recovered from another Corrado, or were they made by your good self? Reason I ask is because the passenger side duct on my '91 G60 fitted perfectly with the stock IC... Why might yours not fit? Are they not originally from a G60, or are they newly made to fit a 16V or VR6? :?

I'd like a plug'n'play loom please, if you are still in business :) Is there much of a waiting list?

Ok, just about to follow your story on that link... Thanks :)

Think I may just give one of the Daves a call, but probably in a month or so, when my wallet feels slightly less bruised... :wink: Anyway, I have to enjoy my newfound (estimated) 190bhp for a while before I raise the bar again! :lol: Speaking of which, is there any point in uprating the brakes if you're under 200bhp? How would you trigger misting of the intercooler (as I think you meant, not CC) from the throttle position? What would you use as a pump to drive the nozzles? Thanks for the info, it's good to get someone's first-hand experience, and an achievable target to aim at. :)

I have a facelifted '92 G60 with ABS and it has no brake ducts in the front arches. Does anyone have a partcode for the panels/ducts, or know a supplier who can provide them? Thanks! :)

Call me Mr. Retentive, but I like to get the basic package right before going for world domination :wink: :lol: But it is a learning curve - getting to know what's relevant and what's not. Great fun though, and I foresee many hours spent trawling the forum for nuggets of knowledge!

Well... part one begins on Monday - a charger refurb, plus 68mm pulley and chip, and stand-alone oil supply :D Will dyno it a couple of weeks later once the G60 has bedded down (my local tuner said £30 for setting up, a couple of runs + printouts), to get a new baseline :wink: More plans beyond that, but £1k is enough for one day! Does anyone know what you can wring out of the G60 engine without modding the heads/bottom end? This is my daily driver (mainly because Corrados are so rewarding to drive!) so I'm not really interested in any mods that will need a rebuild after each trip to the shops :lol: I'll see if I can barn up a design for a ghetto chargecooler :wink: It may never get past the drawing board, but will be good fun. D*mn I love being a Corrado owner. :D

Love the idea of the barrel chargecooler, just wish that they made one a bit smaller, a bit cheaper, and rated to 250bhp... That would probably be all I'd need, especially if I get to having boost temps of Wonder if I could fab one from an extruded honeycomb of aluminium... :) Big dreams, little expertise :(

Thanks cheesewire. Any G60 bods know if the TT's temp sender is compatible with the G60's ECU? Anyone, anyone? I wonder if using phenolic washers between the G60 mount and the engine block would 'eliminate' heat transfer... One for the G-werks/PSD boys I think! I know G-Werks sell phenolic insulators for the inlet manifold, so perhaps the same principle could be applied here. My '36C' temp for the air was a bit 'theoretical' and assumes that there are no other heat sources nearby that would significantly interfere with the simple process of compressing the air... Blatantly not the case in my current (stock) setup :( But if the air coming out of the charger on full boost is only 40-50C because the charger body is not unnecessarily hot, then the stock IC may be able to hack it and give me relatively cool intake temps :D What's the rule of thumb? For every 10C drop in intake temp, you have 3% more oxygen, so 3% more power available? 8)

Ditto those questions! I'm seriously considering the stand-alone oil supply but Andy T's comments sent a shiver down my spine :pale: But... I seem to recall that as long as the oil is rated for use within the working temps then it's all fine, and you shouldn't get premature wear because the oil will be lubricating properly. Not sure about the clearances and seals though... An added benefit is a much lower charge temperature, with lots more lovely oxygen in it :D I also like the idea that the usual oil+grit+sludge that circulates through the engine (oil filter notwithstanding) won't be going through the delicate internals of the charger when a separate 'clean' oil feed is used. Anyone with the engineering nous and experience to answer those questions - go right ahead, please! :wink:

Thanks - good idea. I noticed on the forced induction VR6 thread that the late 1.8T temp sensor(?) is much more responsive than the stock Corrado unit, and that mounting it in the airflow inside the throttle body gives the most accurate readings for the ECU to act upon - is that also good practice and relevant for the G60 engine? If so, is there a VAG partcode to be had? :wink: And who can I get to bore a hole in my TB? I think that most of the heat in the charger must be conducted through from the engine via the oil feed and the metal mounting brackets... Don't think it can be internal friction otherwise my charger wouldn't have lasted 85k miles and still be providing sensible boost. I'm no expert though! :? A standalone charger oil supply kit would appear to keep the body of the charger (and the air inside) cooler:

Leave the fan on then :wink: Got it. :shock: Sweet! :) The only downside in my G60 would be the extra weight (and complexity of plumbing) added - although on a stock unlightened G60 the kerb weight increase would probably be less than when filling up the fuel tank! VR6 turbo - so what's that generating - about 350bhp? :wink: :D Yep, can see that would make sense. Which chargecooler are you using? Seems that the chargecooler.co.uk barrel design is pretty good, but a bit more expensive than the 'entry level' ones... Cheers

For a geographical overview of the breakers listed above, see this map: http://maps.google.co.uk/maps/ms?f=q&hl ... 6&z=6&om=1 :wink:

Er, think I may be able to answer one of my own questions :oops: correct me if I'm wrong! 2) Assuming ambient temp is 18C (average) then air out go the G60 compressed to 14psi/1bar (eg. 68mm pulley on a rebuilt charger) would be doubled in pressure and hence doubled in temperature, to approx 36C... So why does the boost pipework get so d*mn hot? Is it heat soak from all the lovely 100+C oil that's lubricating the charger? Heat soak from the hot engine bay into all those lovely black plastic boost pipes? If so, would a standalone oil supply (as offered by Pitstop) and polished metallic boost pipes not be better options for keeping the boost temp down? Surely if the stock intercooler has to handle only 40C it would be a more elegant solution than having the charger body/pipes heat the air to nearly 100C then fit a massive cooler of some description to take all that heat away again??? I realise that there's some heat transfer directly through the metal mounts and fixings from the engine to the charger, which would be tricky to completely remove, but am I missing something here? :? On that note, would people recommend an exhaust manifold wrap to keep temps in the engine bay down? My bro (a Golf nut) says that the 8 valve non-crossflow engine suffers from heat transfer from exhaust to inlet as one is just below the other!

Lots to digest here! :? A few of questions though for all contributors of this thread: 1) To avoid heat soak/rising water temps in a chargecooler setup, would you run the pre-radiator fan continuously? 2) What kind of boost temperatures would you see going into a chargecooler from a G60 running 14psi? 3) Given the boost temp for 2) above, what could the chargecooler outlet air temp be? (lots of factors, I know, but gimme a ballpark) All that I've read so far makes me think chargecooler rather than intercooler or water injection, but it all depends on what you're after... :wink: Thanks!

How hard would it be to have the water pump for the chargecooler switch off when you are sat in traffic (or when moving at Or is that all just too complex? :? I'm trying to work out the best cooling upgrade to my stock intercooler - seems like I'm not alone! :wink: My G60's being rebuilt at G-Werks on Monday, so I will be chatting with the guys there - I guess it mainly comes down to budget and how much work you want to do/are able to do yourself. Interesting to get lots of opinions and experiences on these options though :)