VOLKSWAGEN CORRADO 1993 Repair Manual

SCHEDULED SERVICES
Article Text (p. 39)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:22PM³ ³ Drain, Refill and Bleed Brake System Fluid ³
ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´
³
³ Drain, Flush and Refill Engine Coolant ³
ÃÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´
³ Lubrication Specifications
³
ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´
³ Application Specification
³
³
³
³ Automatic Transaxle ............................. Dexron-IIE ATF
³
³ Brake Fluid ..................... SAE J1703 Or DOT 4 Brake Fluid
³
³ Coolant ........................ 50/50 Mix Ethylene Glycol/Water
³
³ Engine Oil
³
³ Ambient Temperatures
³
³ Greater Than 50
ø F (10øC) .............. SAE 20W-50 API SG/CD ³
³ 14
ø-50øF (-10ø To +10øC) ............... SAE 10W-40 API SG/CD ³
³ Less Than 14
øF (-10øC) .................. SAE 5W-30 API SG/CD ³
³ Wheel Bearings ..................... NLGI Grade 2 Category GC-LB
³
³ Steering Linkage (1)(2) ............ NLGI Grade 2 Category GC-LB
³
³ Ball Joints (1)(3) ................. NLGI Grade 2 Category GC-LB
³
³ Manual Transaxle ................ SAE 80W API GL-4 Or SAE 75W-90
³
³ Synthetic Transmission Oil G 50
³
³ Power Steering Fluid ................ VW Hydraulic Oil G-002-000
³
³ Weatherstrip ........................ Dielectric Silicone Grease
³
³ Final Drive (Differential) ...... Synthetic Transmission Oil G 50
³
³ SAE 75W-90
³
³
³
³ (1) - Use low pressure grease gun to prevent seal damage.
³
³ (2) - Fill until lubricant squeezes out from the base of seals.
³
³ (3) - Fill ball joint until seal starts to swell.
³
ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´
³ Fluid Capacities
³
ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´
³ Application (1) Quantity
³
³
³
³ Automatic Transmission ......................... 3.2 Qts. (3.0L)
³
³ Cooling System
³
³ 1.8L ......................................... 6.8 Qts. (6.5L)
³
³ 2.8L V6 ...................................... 9.1 Qts. (8.6L)
³
³ Engine Oil (2)
³
³ 1.8L ......................................... 4.3 Qts. (4.0L)
³
³ 2.8L V6 ...................................... 6.3 Qts. (6.0L)
³
³
³
³ (1) - Capacities are recommended or calculated levels. Always use
³
³ dipstick (if available) to measure level.
³
³ (2) - Includes filter change.
³
ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ LUBRICATION SPECIFICATIONS
LUBRICATION SPECIFICATIONS TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Fluid Specifications

SCHEDULED SERVICES
Article Text (p. 40)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:22PM
Engine Oil (1)
Ambient Temperatures
Greater Than 50øF (10øC) .............. SAE 20W-50 API SF/CD
14
øF To 50øF (-10øC To +10øC) ......... SAE 10W-40 API SF/CD
Less Than 14
øF (-10ø C) ................ SAE 5W-30 API SF/CD
Brake Fluid ........................ SAE J1703 (DOT 3 Or DOT 4)
Power Steering Fluid ......................... VW Hydraulic Oil
(G 002000) Or Equivalent
Automatic Transmission ........... Dexron-IIE ATF Or Equivalent
Manual Transaxle .......................... SAE 80W API GL-4 Or
SAE 75W-90 (G50 Synthetic Gear Oil)
Final Drive (A/T & M/T)
(Differential) .......... SAE 75W-90 (G50 Synthetic Gear Oil)
Wheel Bearings .................... NLGI Grade 2 Category GC-LB
Drive Shaft U-Joints .............. NLGI Grade 2 Category GC-LB
Steering Linkage (2)(3) ........... NLGI Grade 2 Category GC-LB
Ball Joints (2)(4) ................ NLGI Grade 2 Category GC-LB
Weatherstrip ....................... Dielectric Silicone Grease
(1) - SAE 15W-40 or 20W-40 engine oil is recommended for extreme
conditions or extended highway operation.
(2) - Use low pressure grease gun to prevent seal damage.
(3) - Fill until lubricant squeezes out from the base of seals.
(4) - Fill ball joint until seal starts to swell.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ FLUID CAPACITIES
FLUID CAPACITIES TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Quantity (1)
A/C System R-12 Refrigerant
1990-92 (up to 7/92) ............................. 37-40 Ozs.
A/C System R-134a Refrigerant (2)
1993-94 (from 7/92) ........................... 28.2-31.8 Ozs.
Cooling System
4-Cyl. ...................................... 6.8 Qts. (6.5L)
V6 .......................................... 9.1 Qts. (8.6L)
Engine Oil (3)
4-Cyl. ...................................... 4.3 Qts. (4.0L)
V6 .......................................... 6.3 Qts. (6.0L)
Fuel Tank
4-Cyl. ..................................... 14.5 Gals. (55L)
V6 ......................................... 18.5 Gals. (55L)
Automatic Transmission
Fluid Change ................................ 3.2 Qts. (3.0L)
Overhaul .................................... 5.9 Qts. (5.6L)
Manual Transmission ........................... 2.1 Qts. (2.0L)
Final Drive
Differential (A/T) (4) ....................... 0.8 Qt. (.75L)

SCHEDULED SERVICES
Article Text (p. 41)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:22PM
(1) - Capacities are recommended or calculated levels. Always use
dipstick (if available) to measure level.
(2) - Use of R-12 in a R134a system will result in SEVERE DAMAGE.
(3) - Includes oil filter change.
(4) - Lifetime fill.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE

SPECIFICATIONS & ELECTRIC COOLING FANS
Article Text
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:23PM
ARTICLE BEGINNING
1993 ENGINE COOLING
Volkswagen Specifications & Electric Cooling Fans
Volkswagen; Corrado SLC, Passat
SPECIFICATIONS
BELT ADJUSTMENT
BELT ADJUSTMENT TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Specification
A/C Compressor
Passat GL
New ............................ (1) 72 INCH Lbs. (8 N.m)
Used ........................... (1) 36 INCH Lbs. (4 N.m)
Alternator
Passat GL .................. (1) (2) 72 INCH Lbs. (8 N.m)
Power Steering
Passat GL ................................. 13/64" (5 mm)
Serpentine Belt
Corrado SLC, Passat GLX ............................. (3)
(1) - Turn tensioning nut on toothed rack with Torque Wrench
(VAG1410) and Ring Insert (SW VAG 1410-2).
(2) - Start engine and let it idle for 5 minutes. Loosen
bolts and retighten belt to specification.
(3) - Serpentine belt tension automatically adjusted by
tensioner.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ COOLING SYSTEM SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS (1)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄModel Specification
Coolant Replacement Interval ................ 30,000 Miles
Corrado SLC ............................. 9.1 Qts. (8.6L)
Passat GL ............................... 5.9 Qts. (5.6L)
Passat GLX .............................. 9.1 Qts. (8.6L)
(1) - Cooling system includes heater.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ ELECTRIC COOLING FAN
NOTE: If detonation is a problem, it is possible that the cooling

SPECIFICATIONS & ELECTRIC COOLING FANS
Article Text (p. 2)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:23PM
fan is not coming on at proper temperature and engine is
overheating.
Corrado SLC, Passat GLX
The cooling fan is either a 1 or 2-speed motor. If vehicle is
equipped with single-speed motor, the fan comes on at 198-207øF (92-
97
øC) and turns off at 183-196øF (84-91øC). If equipped with a 2-speed
motor, low speed of cooling fan should come on at 198-208
øF (92-98øC)
on vehicles without A/C, or 183-207
øF (84-97øC) on vehicles with A/C.
Low speed will shut off at 183-196
øF (84-91øC) on all vehicles. High
speed comes on at 210-226
øF (99-108øC) on vehicles without A/C, or
201-226
øF (94-108øC) on vehicles with A/C. High speed will shut off at
196-220
øF (91-104øC) on all vehicles.
After-Run Thermoswitch
An after-run switch is used to help prevent fuel
vaporization. The thermoswitch turns cooling fan on when temperatures
in engine compartment exceeds 230
øF (110øC), and turns it off at 217øF
(103
øC).
Passat GL
The cooling fan is a 2-speed motor. Low speed of cooling fan
should come on at 198-207
øF (92-97øC) and will shut off at 183-196øF
(84-91
øC). High speed comes on at 210-221øF (99-105øC) and will shut
off at 196-208
øF (91-98øC).
TROUBLE SHOOTING
NOTE: Trouble shooting information not available from manufacturer.
TESTING
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Corrado SLC & Passat GLX (2.8L)
1) Ensure engine is cold. Connect Scan Tester (VAG 1551) to
Data Link Connectors (DLC) located in center console, in front of
shift lever.
2) Start engine and allow it to idle. With scan tester in
READ TEST VALUE BLOCK function, select group No. 01 and read coolant
temperature value in field No. 2 of scan tester. Temperature value
must increase uniformly without interruption. If value increases as
specified, select END OUTPUT function on scan tester.
3) If displayed value does not change or if engine
malfunctions during certain temperature ranges, turn ignition off and
measure engine coolant temperature sensor resistance. See ECT SENSOR
LOCATION table. Replace ECT sensor if resistance is not within
specification. See ECT SENSOR RESISTANCE table.
Passat GL
1) Ensure engine is cold. Connect Scan Tester (VAG 1551) to
Data Link Connectors (DLC) located in center console. Start engine and

SPECIFICATIONS & ELECTRIC COOLING FANS
Article Text (p. 3)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:23PM
allow it to idle. With scan tester in READ MEASUREMENT BLOCK function,
read coolant temperature value in channel No. 1 of scan tester.
2) If temperature value increases uniformly without
interruption, sensor and its circuit are okay. Select END OUTPUT
function on scan tester. If display value is incorrect, test wiring
harness for open or short circuit. See Corrado SLC WIRING DIAGRAMS,
or Passat WIRING DIAGRAMS articles.
3) If necessary, use test leads from Adapter Kit (VAG 1594)
to measure ECT sensor resistance. See ECT SENSOR LOCATION table.
Replace engine coolant temperature sensor if not within specification.
See ECT SENSOR RESISTANCE table.
ECT SENSOR RESISTANCE TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄTemperature
øF (øC) Ohms
68 (20) ........................................ 3000-2000
86 (30) ........................................ 2000-1500
104 (40) ....................................... 1500-1000
122 (50) ........................................ 1000-800
140 (60) ......................................... 700-500
158 (70) ......................................... 500-375
176 (80) ......................................... 375-275
194 (90) ......................................... 275-225
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄECT SENSOR LOCATION TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄModel Location
Corrado SLC & Passat GLX
Blue, Brown & Yellow Sensor . On Radiator Near Upper Hose
Passat GL .............................. Below Distributor
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE

STARTER
Article Text
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:23PM
ARTICLE BEGINNING
1993 ELECTRICAL
Volkswagen Starters - Bosch
Volkswagen; Corrado SLC, Passat
DESCRIPTION
Starter is a brush type, series-wound electric motor with an
overrunning clutch. Field frame is enclosed by commutator end frame
and drive bushing, and carries pole shoes and field coils. A splined
armature shaft drive end carries drive assembly.
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in
GENERAL INFORMATION.
ON-VEHICLE TESTING
STARTER DOES NOT CRANK ENGINE
1) Ensure battery is fully charged. Make sure electrical and
ground connections are clean and tight. With ignition switch in START
position, measure voltage at spade terminal of starter solenoid.
Reading should be at least 8 volts. If voltage is as specified, check
engine for mechanical problems. If voltage is not as specified, go to
next step.
2) Measure voltage at ignition switch. If reading is at least
8 volts, check wiring between ignition switch and starter solenoid. If
voltage is not as specified, replace ignition switch.
3) Measure voltage at field (starter) terminal of starter
solenoid. If reading is 8 volts or more, repair or replace starter. If
reading is less than 8 volts, replace starter solenoid.
NOTE: On vehicles with automatic transmission, also check
park/neutral switch.
STARTER CRANKS TOO SLOWLY
Ensure engine crankcase is filled with recommended viscosity
oil. Check charging system to ensure battery is fully charged. Make
sure electrical and ground connections are clean and tight. If starter
still turns slowly, repair or replace starter.
VOLTAGE DROP TEST
Starter Main Terminal
Connect a voltmeter between starter main terminal and starter
body. Disconnect ignition coil positive terminal and operate starter.

STARTER
Article Text (p. 2)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:23PM
Voltage reading should not be more than one volt less than battery
voltage. If a larger voltage drop is indicated, circuit between
battery and starter terminal may be defective.
Main Starter Case
Connect a voltmeter between positive battery terminal and
starter motor "M" terminal. With ignition off, operate starter for 2-3
seconds. Battery voltage should be present, then drop to less than one
volt. If voltage is greater than specification, high resistance may be
present in circuit. Go to ACROSS SOLENOID SWITCH test.
Across Solenoid Switch
Connect a voltmeter between 2 starter solenoid terminal stud
connections. With ignition disconnected, operate starter for 2-3
seconds and note meter reading. Initially, battery voltage should be
present, then voltage should drop to less than .5 volt. If voltage is
not as specified, check for damaged switch or loose or dirty
connections. If high resistance is present, terminal may be loose or
corroded.
Ground Return Line
Connect a voltmeter between battery ground terminal and
starter main housing. With ignition off, operate starter for 2-3
seconds. If ground is okay, voltage reading should be less than .5
volt. If reading is .6 volt or more, high resistance is present in
ground return side of circuit.
BENCH TESTING
STARTER SOLENOID
1) Remove bridge strap connecting solenoid to motor. Check
windings by connecting a 12-volt self-powered test light between
solenoid main terminal STA and solenoid body. If light illuminates,
both windings are satisfactory.
2) Ensure that contacts open and close satisfactorily by
connecting a 12-volt self-powered test light between starter solenoid
main terminals. Test light should not illuminate.
NOTE: Step 3) uses a non-powered (standard) test light.
3) Connect a test light to STARTER terminal of solenoid and
ground. Apply voltage to STA and BAT terminals of solenoid. Solenoid
should be heard to operate as contacts close and test light should
illuminate. When voltage is removed from STA terminal of solenoid,
test light should go out.
STARTER LOAD (LOCK) TEST
With starter on test bench, lock starter drive pinion.
Voltmeter should read 4.5 volts and ammeter should read 700-800 amps.

STARTER
Article Text (p. 3)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:23PM
STARTER NO-LOAD TEST
With starter on test bench, operate starter and check
ammeter, voltage, and RPM. Readings should be within specification.
See STARTER NO-LOAD TEST SPECIFICATIONS table.
STARTER NO-LOAD TEST SPECIFICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄVolts Amps RPM
11.5 ........... 65-95 .......... 6500
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ REMOVAL & INSTALLATION
CORRADO SLC & PASSAT
CAUTION: Failure to use Support Beam (VW 10-222A) and Leg Set (VW
10-222A/1) may result in misalignment of
engine/transmission assembly.
Removal & Installation
1) Disconnect negative battery cable. Support
engine/transmission assembly with Support Beam (VW 10-222A) and Leg
Set (VW 10-222A/1). See Fig. 1. Remove engine mount bolts. Remove
rubber engine mount lower nut and clamp screw. Remove engine mount.
2) On Passat, cut and remove starter and alternator wiring
harness tie straps. On all models, disconnect wiring and remove
starter. To install, reverse removal procedure. Tighten starter
mounting bolts/nuts to specification. See TORQUE SPECIFICATIONS table
at end of article.Fig. 1: Removing Starter (Corrado SLC, Passat)
Courtesy of Volkswagen United States, Inc.

STARTER
Article Text (p. 4)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:23PM
OVERHAUL
For overhaul, see exploded view of typical Bosch starter. See
Fig. 2.Fig. 2: Exploded View of Bosch Starter (Typical)
Courtesy of Volkswagen United States, Inc.