In 1992, with the introduction of the VR6 engine, the Volkswagen Corrado underwent several subtle, yet significant styling modifications from the G60. To accommodate the larger engine, hood creases went from downward to upward. Interior controls assumed a softer look with more rounded control stalks and switches.
The front grill was changed as well. From seven horizontal slats and central emblem, to four horizontal slats and a slightly protuberant central emblem. The updated grill brought Corrado in line with other 92 VW front end grills and has a more three dimensional look than the 90 grill. Even the Passat, with a once smooth front end, got a grill in 94/95.
The new grill for 92 onward VR6 Corrados is part number 535 853 653 A 01C. It is made in Germany of high impact plastic and can be special ordered through your local VW dealer. My dealer charged USD $80.82 for the grill. I also recommend ordering a new VW emblem to fit your new grill. The emblem is VW part number 1H0 853 600 DRR. Mine was made in USA, and costs about $9. The reason to get a new emblem is that it comes with a gasket that fits on the new grill. Plus, a new emblem will look all shiny and fresh for your new grill.
When your new grill arrives, the first thing you will notice is that it's tabs do not fit into the spaces the old grill's came out of. No problem. With the Leipsic Drill-Free Grill Modification Method, you will have that new grill on in no time.
The only tools you will need are: Krazy Glue, Tie-Wraps, and a handy Swiss Army Knife.
The old grill has two clips on top which clip into long holes on the metal grill upper cross member. There are two tabs on the bottom of the old grill which fit into two holes in the bottom cross member. The new grill has three clips on top, and three larger tabs on the bottom. The absolute length of the new grill is about 1cm longer than the old grill, but it still fits right in between the two light housings.
Now, if you want to get a power drill and cut new tabs into your metal cross members to fit the new grill, that is your choice. The upper cross member would be an easier cut, but the bottom one would be harder with it's more contoured metal. Besides, this writer has a constitutional aversion to cutting on a car. Be that as it may, no cutting is necessary on your car with the Leipsic DrillFree Grill Method.
The old grill looks like this:
^ ^ <- clips
The new grill looks like this:
^ ^ ^ <- clips
The first thing you do is slice off the three bottom tabs. Use a file to cut down the outer length of the tab, then a knife can remove the rest of the tab. A little bending and twisting will get it right off too.
Don't break up the tabs themselves, you will need
them. Each tab has a rectangular base which serves
to elevate the grill a bit above the lower metal cross
member. For the new grill placement, this base is
about two times too high. So just cut it in half.
Here's a drawing attempt:
| | <- tab
| |
------
| | <- base
| | <- cut off half this lower part to halve base
Then get some fantastic Krazy Glue, or any super plastic bondo stuff should work. This glue completely melts the plastic beneath, and when it is applied to both sides, it forms a new plastic bond between the pieces. I rough up the plastic by scoring it with a knife, to improve bonding.
With your new tabs with bases sliced in half, line up the place on the new grill where the old grill has it's bottom tabs. This is easy to do. Just put the grills side by side and mark the place for the new tab placement on the new grill. The new tabs should be lined up with the rear margin of the new grill.
Then scratch up the place for the new tabs, apply plastic bond glue, put new tab on, hold until bond has taken, and repeat for the second tab. Easy. Wait for these to dry before installing grill.
Now, the three upper clips. Slice them all off as well. This is much easier than the bottom tabs. You don't need to save the upper clips, we won't use them.
Again, line up the old grill with the new one and mark the places where the old grill upper clips are on the new grill. These places are also directly above the new lower tab placements.
Use the leather awl tool on your Swiss Army Knife to punch a small hole in the upper grill plastic just before the small inner ridge. This hole can be small, but enlarge it with the knife blade to make a 0.5 cm slat. These are the holes through which the tie-wraps will go.
Now, the glue is dry, and your upper slats are cut. Take the VW emblem and snap it into place keeping the black gasket on the emblem. The old grills do not use the black emblem gasket. The new grill does use the gasket, for good effect. The G60 emblem can be unclasped and glued into it's new place.
Now it is time to fit your new grill into place. Gently place the lower tabs into the lower cross member holes. Then gently bow the grill until the upper edge meets the upper grill cross member. Take your tie-wraps, thread them through the holes in the grill and then place them through the holes in the cross members where the clips used to be. Tighten the tie-wraps, trim, and you new grill is in place!
If, perchance, the lower tabs were to give way while driving or struck by an errant missile, the grill is still attached by the tie-wraps on top.
Complement your new sporty, modern grill with a front grill lip spoiler, and you're fully ready for action!
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