VOLKSWAGEN CORRADO 1990 Repair Manual

* SYMPTOM CHECK LIST *
Article Text (p. 14)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:40PMFig. 12: Water Leak & Wind Noise
END OF ARTICLE

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:40PM
ARTICLE BEGINNING
1989-90 VOLKSWAGEN ENGINES
1.8L 8-Valve & 1.8L 16-Valve 4-Cylinder
1989-90
Cabriolet, Fox, Golf, GTI, Jetta, Jetta GLI
1990
Corrado
* PLEASE READ THIS FIRST *
NOTE: For engine repair procedures not covered in this article,
see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article
in the GENERAL INFORMATION section.
ENGINE IDENTIFICATION
Engine identification number is stamped on a machined pad,
left side of engine block, near distributor assembly. See Fig. 1. The
first 2 characters designate engine code.
ENGINE IDENTIFICATION CODES TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Engine Code
1.8L 8-Valve 4-Cylinder
Cabriolet ........................................ JH
Fox .............................................. UM
Golf, Golf GT & Jetta ............... (1) GX, RV or PF
1.8L 16-Valve 4-Cylinder
GTI & Jetta GLI .................................. PL
(1) - Code GX is a 1.8L with 85 HP. Code RV is a 1.8L
with 100 HP. Code PF is a 1.8L with 105 HP.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄFig. 1: Engine Identification Number Location
Courtesy of Volkswagen United States, Inc.

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
Article Text (p. 2)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:40PM
NOTE: Match mark engine mounts to ensure original alignment is
achieved after installation. On vehicles with A/C and power
steering, remove components with hoses attached and secure
out of way.
ENGINE R & I (EXCEPT FOX)
REMOVAL (EXCEPT FOX)
1) Disconnect and remove battery. Open fuel tank fill cap and
radiator cap. Remove intake air duct. On 16-valve engines, remove
intake manifold assembly. On vehicles with A/C, remove trim panel and
lower apron. Remove condenser from crossmember and radiator. Remove
all duct work. Mark and disconnect A/C and cooling fan electrical
connectors. Remove accessory belts.
2) On Golf, GTI and Jetta models, leave A/C hoses attached
and remove A/C compressor. Pivot A/C condenser and compressor to side
of vehicle and secure.
3) On Cabriolet and Scirocco models, remove alternator and
timing belt cover. Remove 3 A/C bracket Allen head bolts behind timing
belt cover. Remove A/C bracket support brace. Remove A/C compressor
bracket bolts. Leave hoses attached and secure A/C compressor with
bracket out of way.
4) On all models, open heater controls. Remove cooling hose
from thermostat housing flange and drain coolant. Remove flange. Mark
and remove all cooling system hoses (as necessary).
5) On Golf, GTI and Jetta models, remove grille from radiator
support. Disconnect electrical connectors at radiator support. Remove
radiator-to-support bolts. Remove radiator support using care not
damage headlights. Remove radiator, fan and shroud assembly.
6) On all models, remove axle shafts from transaxle. See FWD
AXLE SHAFTS article in the DRIVE AXLES section. Mark and disconnect
shift linkage and speedometer cable. Mark and remove electrical
connectors and vacuum hoses (as necessary). Disconnect throttle,
cruise and kickdown cables (if equipped). Leave fuel lines connected
and remove cold start injector and warm-up regulator.
7) Remove fuel injectors and install protective caps and
plugs. Remove rear engine mount. Remove complete transaxle mount. On
Cabriolet models, remove right front tire assembly. Remove right and
left engine mount through bolts.
8) On all models, install engine sling on engine lift hooks.
Carefully raise engine and transaxle out of vehicle. Separate
transaxle from engine (if necessary).
INSTALLATION
1) To install, reverse removal procedure. Engine alignment
adjustment is necessary whenever engine is removed or mounts are
loosened. To adjust, loosen through bolt on engine mount "A". Loosen
transmission transaxle mount "B" bolts. Loosen front engine mount and
bracket. See Fig. 2.
2) Lightly rock engine and transaxle to allow position to

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
Article Text (p. 3)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:40PM
shift as necessary. Evenly tighten mount bolts in reverse order of
loosening. Fill fluids to proper level. Adjust clutch pedal (if
equipped). Tighten all bolts and nuts to specifications.
ENGINE R & I (FOX)
REMOVAL (FOX)
1) Disconnect negative battery cable. Open heater valve,
coolant expansion tank and drain radiator through lower radiator hose.
Mark and disconnect all heater hoses. Disconnect electric cooling fan
and thermo switch. Remove lower and side radiator mounting bolts.
Remove fan, shroud and radiator. Remove M/T clutch cable (if
equipped).
2) Mark and disconnect electrical wiring and vacuum hoses (as
necessary). Disconnect throttle, cruise and kickdown linkage (if
equipped). Remove fuel injectors and install protective caps and
plugs. Leave fuel lines attached and remove cold start valve. Remove
charcoal canister and set aside.
3) Remove 3 upper engine-to-transaxle bolts. Remove intake
air duct. Remove left and right engine mount nuts. Disconnect and
remove starter assembly. Remove 2 lower engine-to-transaxle bolts.
Remove transaxle inspection cover plate. Disconnect exhaust inlet pipe
support and separate inlet pipe from exhaust manifold.
4) Support transaxle. Attach engine sling to engine lifting
hooks. Raise engine/transaxle until engine clears engine mounts.
Ensure transaxle is supported. Remove remaining engine-to-transaxle
bolts. Lift and separate engine from vehicle without transaxle.
INSTALLATION
Lubricate transaxle main shaft splines and contact area
between clutch release bearing and clutch pressure plate with MoS2
grease. DO NOT lubricate guide sleeve for clutch release bearing. To
complete installation, reverse removal procedure. DO NOT reuse self-
locking nuts. Ensure engine mounts are installed to original location.
Tighten engine mounts and subframe bolts with engine running at idle.

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
Article Text (p. 4)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:40PMFig. 2: Engine/Transaxle Alignment
Courtesy of Volkswagen United States, Inc.
INTAKE MANIFOLD R & I
Removal and installation procedure is not available from
manufacturer. See TORQUE SPECIFICATIONS table at end of this article.
EXHAUST MANIFOLD R & I
Removal and installation procedure is not available from
manufacturer. See TORQUE SPECIFICATIONS table at end of this article.
CYLINDER HEAD R & I
REMOVAL
No removal procedure available from manufacturer. Cylinder
head may be removed with engine in vehicle. Match mark all components
for installation reference. Timing belt must be removed. See TIMING
BELT R & I in this article. See Fig. 3 or 4. Remove cylinder head
bolts in reverse sequence of installation. See Fig. 5. Replace
cylinder head bolts after loosening or removing.

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
Article Text (p. 5)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:40PMFig. 3: Exploded View of 16-Valve Cylinder Head
Courtesy of Volkswagen United States, Inc.

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
Article Text (p. 6)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:40PMFig. 4: Exploded View of 8-Valve Cylinder Head
Courtesy of Volkswagen United States, Inc.
INSPECTION
Thoroughly clean all gasket mating surfaces. Check cylinder
head for warpage. The 8-valve cylinder head can be machined and 16-
valve cylinder head cannot be machined. Check camshaft(s). See
INSPECTION under CAMSHAFT R & I in this article. See ENGINE
SPECIFICATIONS at end of this article.
NOTE: DO NOT reuse antifreeze after replacing cylinder block,
cylinder head, head gasket, radiator and/or heater core.

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
Article Text (p. 7)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:40PM
INSTALLATION
1) Ensure marking on cylinder head gasket is properly
positioned and install gasket on cylinder block. Do not use any type
of sealant. Carefully position cylinder head on cylinder. Install head
bolt Nos. 9 and 10 hand tight to ensure cylinder head position.
Install remaining head bolts hand tight.
2) Tighten cylinder head bolts in sequence to specifications.
See Fig. 5. See TORQUE SPECIFICATIONS table at end of this article. No
further information is available from manufacturer.Fig. 5: Cylinder Head Bolt Tightening Sequence
Courtesy of Volkswagen United States, Inc.Fig. 6: Exploded View of Timing Belt Components
Courtesy of Volkswagen United States, Inc.
TIMING BELT R & I
REMOVAL
Information not available from manufacturer. Use exploded
view for component locations. See Fig. 6. Match mark all components to
ensure reassembly to original position.
INSTALLATION (8-VALVE)

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
Article Text (p. 8)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:40PM
1) Align flywheel/flex plate "O" mark with pointer. This is
TDC. Remove distributor cap and check position of ignition rotor.
Rotate intermediate shaft and position rotor at No. one cylinder mark
on housing. See Fig. 7.Fig. 7: Aligning Ignition Rotor
Courtesy of Volkswagen United States, Inc.
2) With intermediate shaft/ignition rotor positioned, rotate
crankshaft and align mark on crankshaft pulley with mark on
intermediate shaft sprocket. Position camshaft sprocket mark even with
valve cover surface. See Fig. 8. Install timing belt.Fig. 8: 8-Valve Timing Mark Alignment
Courtesy of Volkswagen United States, Inc.
3) Rotate tensioner clockwise to tighten belt and install
lock nut. Proper tension is achieved when belt can be twisted 90
degrees. See Fig. 9. Rotate crankshaft 2 revolutions and check timing
mark alignment. To complete installation, reverse removal procedure.

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
Article Text (p. 9)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:40PMFig. 9: Proper Timing Belt Tension
Courtesy of Volkswagen United States, Inc.
INSTALLATION (16-VALVE)
1) Install timing belt around crankshaft and intermediate
shaft sprockets. Install lower timing belt cover. Install vibration
damper, noting offset holes. If valve cover is installed, mark on
front of camshaft sprocket must align with mark on valve cover. If
valve cover is removed, place camshaft sprocket mark even with valve
cover surface. See Fig. 10.Fig. 10: 16-Valve Timing Mark Alignment
Courtesy of Volkswagen United States, Inc.