Heater Matrix problem

[AngusL 10]

Hi all - My first post.

 

You already know but what a fantastic car the VR6 Corrado is ! I only just found out after 20 odd years !

 

I recently bought a VR6 Corrado and am slowly working my way through all of the issues. On my first run home the car popped the heater matrix. After much reading here and across the various VW sites I decided to tackle the issue last weekend. I purchased a VALEO heater matrix and was given a HELLA (RHD) as a replacement - the supplier did discuss this with me prior to me receiving the Hella unit so it wasnt a surprise but was a big difference in item price.

 

I have never done this swap before and lets face it until you strip out the original which as you all know is a HUGE task. I decided to take out the entire dash as I had a few other issues to sort out under there. One of which I suspect is a dodgy earth causing intermittent speedo and rev counter operation.

 

Anyway, dash out after a few hours. If I can give you one tip its to get a small cordless screwdriver with loads of bits and bit lengths. It really does make this job a million times easier and you dont damage screw heads or threads. Just be careful on reassembly as the torque could overdo it for you. As it tightens hold the driver "loosish" so that when it is tight it can move enough to stop the power - Hey it works for me.....

 

OK so here is the problem - After taking everything out yes I have a mountain of parts and wires everywhere in the car now, Replaced the New Hella unit and guess what the pipes are too short to exit the car so joining the coolant pipes is impossible.

 

Be warned - I reported the issue to the supplier who have been brilliant in sorting the issue out, However HELLA have categorically stated its the correct part and admit no liability. Screw the bloody liability I want my car part and to be able to put it back together ! I have insisted on a VALEO replacement part and this has been sourced in Germany which is being delivered later this week I hope.

 

On the WANAPART UK web site they have 2 HELLA items listed 1 LHD and 1 RHD. If you order the RHD item - IT WONT FIT your Corrado!

 

 

Pics attached so have a look and you can easily see what I am talking about. The other two pics are the mess my car is in after everything is stripped out of the dash to do this task... Obviously not the electric heater as it was too cold for my liking.

 

I did the Heater flap refurb using Duck tape and a double sided spongy tape for the edges which is covered with more duck tape.

 

The stiffness in the heater flap operation was fixed by a small amount of WD40 into the flap rotating plastic joints - Really easy and a massive difference to the clunky operation before.

 

I will update this if I can with the outcome and result of replacing my dash.

[Hairyarse 10]

Hi Angus

 

Well it took you 20 years but you got there in the end! lol Me too, I had never been in a Corrado until this August when I picked up mine and couldn't believe what I'd been missing - it was meant to be!

 

That sucks on the matrix and a good heads-up for everyone else. At least once you're sorted you know you'll never have to do it again! Can you actually see the matrix at all before removing all the dash. I don't think mine has ever been done so it would be useful if check it over I guess, if that's at all possible?

 

Your interior looks nice by the way, how is the rest of the car?

[Sean_Jaymo 0]

I need a beige interior in my life! Good effort, daunting but not impossible,

[AngusL 10]

Hi Andy there are a few items for me to tidy up. The first task I did was the drivers door central locking simply wiggled when the remote door button was pressed. It turned out to be a broken retaining leg on the central lock to door pin push causing the cl rod to jump out of the retainer every time it was operated. After finding out it is now an obsolete part I set about it with a soldering iron to melt the plastic back into its correct shape. I found the broken leg in the base of the door. Some additional support melted into place and it doesn't look far from the original shape.. It is only working consistly now - result. However I found that VW Heritage were able to order some with a few spares from Germany. Should be arriving soon.

 

When I bought the car the previous owner had attemped to fit an Audi set of triple gauges under the heater controls. The centerfielder console dash part was smashed to bits so I have a replacement for that which is going in with the rebuild this weekend.

 

I had a single wiper mechanism which worked fine until the matrix blew then it always stopped at the same point in the sweep. I simply bought a refurbished setup and Lipo wipers and its fine now.

 

You can't see the matrix as its an integral part of the heater. I read that you can take the matrix out without the dash but.... I wanted to refurbished the heater flaps and tidy up the wiring as it looks such a mess. I have a Bluetooth Sony head unit that I would like to fit so that I can connect my phone and have internet radio and phone hands free so seeing the radio connections was also important.... You get the idea. It looks far worse than it is looking at the mess. I am looking fwd to getting it all sorted

 

If anyone is going to do this and by now I think all Corrados will need it sooner rather than later my experience is pay the money and get a VALEO unit it was the original item in the car.

 

An interesting thing is when the matrix blew out there was some steam on the windscreen but no water in the footwells. I have been driving the car for fun every weekend and no water has leaked. I guess this is down to the valve that stops the water leaking out of the cooling system. I have seen pics of water all over the footwells which mine being a 1995 didn't suffer from.

 

I wish that I had bought the car during the summer so that I could have worked on it with a bit of warmth around. Getting there.

 

As you can see I am not afraid to get stuck in and love working on the cars.

 

I got a pleasant surprise before I stripped the dash... The heated leather Recaros do work.

 

Merry Xmas to you all

[Hairyarse 10]

Thanks for the feedback Angus. As you say it makes sense to take the dash out as I'm sure we'd all have other jobs needing to be tackled!

[Drucey 10]

I have a 1.8 16v Corrado. Am thinking of going my heater matrix soon. Will it matter if I do it with out ripping all the dash out? I get the foam spitting from the heater box. Think it's all come out now? Lol, will it matter if I don't replace it? Not brave enough to rip the lot out.. Thanks people :)

[AngusL 10]

Hi Drucey - I am no specialist and have never done this task before - however having taken the dash out it will be easier next time should I have to remove the dash again and the cordless screwey certainly speeds the task up. I read that people break things in removal of the dash like the clips on the back of the heater motor plastic ducting that goes into the Heater box assembly or the arms on the heater flap mechanism. None of this is good and I am aware of it so want to avoid breaking anything. If you read the forum you will see that where the matrix has been done with the dash in there is plenty of talk about using force... Things are going to break and I want my car back together as it was. Perhaps I'm a bit anal but I dont want to introduce new problems into an already old car. Fingers crossed so far I have the bits out flaps recovered and smooth and easy flap operation so far so good. Ok Ok So there was excessive force to get the glove box out but I researched this and it took 2 mins to remove.....Not a problem at all.

 

The only real issue I had that I have not mentioned before is the lower bolt on the engine bay side this holds the heater box to the bulkhead - Just as others stated in the forum it was stuck firmly and only spun when I tried to undo it. I though I would get it out by using mole grips on the square section on the end of the bolt and WD40 on the bolt - Nope no good and that was all that held the box inside so yes I confess i simply pulled it gently but firmly and it did let go on the inside of the car. I am not a person to be beaten easily by this and will be taking the bolt out (Mole grips on the inside of the bolt head) then running a die down the threads to clean them up then epoxy bond the bolt head back in to the heater box and use copper slip grease on the threaded part when it goes back in. It will be as good as new. Then put a plastic sleeve cover over the engine bay thread to stop road salt seizing it again. Famous last words.... My wife says I talk too much Hmmm !

[Jim Bowen 1]

About to do my matrix, ordered a valeo from ebay, going to check with your photos that its the right one. I too am struggling with the heater box removal. Gave up the other night before i broke something.

[Jim 1]

What are you stuck with on it, Jim?

[Jim Bowen 1]

I just didn't find all the bolts, wasn't using a guide so guessed and now realise i missed most of them. Going to attempt again at the weekend, now i have a guide/photos to refer to.

[Drucey 10]

Do they use the same matrix across the models? I need one for a 1.8 16v (g reg)there are lots on eBay or would going to Gsf car parts be ok?

[Jim 1]

I just didn't find all the bolts, wasn't using a guide so guessed and now realise i missed most of them. Going to attempt again at the weekend, now i have a guide/photos to refer to.

 

Kris's guide was pretty handy for the locations of all the bolts so definitely worth double checking that.

[g0ldf1ng3r 13]

Kris's guide was pretty handy for the locations of all the bolts so definitely worth double checking that.

 

Jim - did you manage to publish the pdf on the wiki i sent you which for which i managed to get most of the missing pictures (dead links) from kris's guide? in case the pictures are still not showing in his guide on the wiki

 

i still havent attempted the valver's matrix as i now need to focus on other things to get a MOT on it

[Jim 1]

I honestly completely forgot. I will see about getting it pinned somewhere though this evening if I remember!

[dragon green 4]

Pics show ok for me

http://the-corrado.net/showthread.php?t=45452

[Drucey 10]

Could some one please be kind enough to link me the correct matrix for a (kr) 1.8 16v there are a few on eBay but not sure about make, the right size etc.. Are all corrado matrix the same? 16v and vr6.. Etc. Thanks everybody :)

[dragon green 4]

They are all the same size,I've got a Valeo in mine which I got from the dealers

[Jim Bowen 1]

I could only find one valeo for sale on eBay last week. Tried a few places that advertised them but no one seemed to have one. Not sure if it's a hard to get part or not.

[g0ldf1ng3r 13]

I honestly completely forgot. I will see about getting it pinned somewhere though this evening if I remember!

 

no probs jim - just thought id ask as the kris guide still has quite a few pics missing, though there are more than there used to be

[angus.lougheed 10]

Hi Jim when I was looking I also used Google search. Fingers crossed for this weekend it all goes back together. "One less thing" as Forrest said. Its the pipes on the side of the matrix that were no good. So when talking matrix size be careful as the size... Yes will fit.

[AngusL 10]

Update.. Valeo in, dash back in after I tidied up the wiring. I have a few pics to put up of the matrix to bulkhead bolts because if you see them it becomes obvious that when the two bolts spin just keep turning and they are undoing themselves on the inside. Pics to follow