technical specifications VOLKSWAGEN CORRADO 1990 Repair Manual

MAINTENANCE INFORMATION
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:48PM
ARTICLE BEGINNING
1990-94 MAINTENANCE
Volkswagen Maintenance Information
Corrado G60 (1990-92)
SLC (1992-94 USA)
VR6 (1992-94 Canada)
* PLEASE READ THIS FIRST *
NOTE: For scheduled maintenance intervals and the related fluid
capacities, fluid specifications and labor times for major
service intervals, see SCHEDULED SERVICES article in this
section. Warranty information and specifications for fluid
capacities, lubrication specifications, wheel and tire size,
and battery type are covered in this article.
MODEL IDENTIFICATION
VIN LOCATION
The Vehicle Identification Number (VIN) is located on the
left side of the dash panel at the base of the windshield. The VIN
chart explains the code characters.
VIN CODE ID EXPLANATION
Numbers preceding the explanations in the legend below refer
to the sequence of characters as listed on VIN identification label.
See VIN example below.ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿
³ (VIN) W V W A B 0 5 3 2 M H 0 9 9 7 1 7
³
³ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
³
ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ1 - Manufacturing Country
W * Germany
1 * United States
3 * Mexico
9 * Brazil
2-3 - Manufacturer
VW * Volkswagen
4 - Series
D * 2-Door G60 (1990-92)
E * 2-Door SLC (1992-94 USA)
E * 2-Door VR6 (1992-94 Canada)

MAINTENANCE INFORMATION
Article Text (p. 10)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:48PM
SERVICE LABOR TIMES
SERVICE LABOR TIMES TABLE (HOURS)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ (1)(2) 15,000 (1)(2) 30,000 (60,000)
Application Mile Service Mile Service
Automatic Transmission ..... 1.6 .................. 3.3 (4.2)
Manual Transmission ........ 1.8 .................. 2.7 (3.6)
(1) - Add .2 hr. if equipped with A/C. Add .1 hr. if equipped
with cruise control.
(2) - Add 1.8 hrs. to replace camshaft timing belt (if equipped).
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ LUBRICATION SPECIFICATIONS
LUBRICATION SPECIFICATIONS TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Fluid Specifications
Engine Oil (1)
Ambient Temperatures
Greater Than 50
øF (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
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

MAINTENANCE INFORMATION
Article Text (p. 11)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:48PM
Application 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)
(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.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ WHEEL & TIRE SPECIFICATIONS
Wheel and tire sizes vary according to vehicle and equipment
and can be found on tire information label on each vehicle. Wheel and
tire specifications and tire inflation pressures are listed on a label
found inside fuel tank flap.
NOTE: Snow chains must be used on drive wheels, in pairs only.
WHEEL TIGHTENING
Tighten all wheel lugs to 80 ft. lbs. (110 N.m).
BATTERY SPECIFICATIONS
CAUTION: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure. See COMPUTER
RELEARN PROCEDURES article in the GENERAL INFORMATION
section.
All models use BCI group 41 batteries with cold crank rating

N - REMOVE/INSTALL/OVERHAUL
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:49PM
ARTICLE BEGINNING
1990 ENGINE PERFORMANCE
Removal, Overhaul & Installation
Volkswagen; Cabriolet, Corrado, Fox, Golf GL/GTI,
Jetta, Vanagon
INTRODUCTION
Removal, overhaul and installation procedures are covered in
this article. If component removal and installation is primarily an
unbolt and bolt-on procedure, only a torque specification may be
furnished. See TORQUE SPECIFICATIONS at the end of this article.
REMOVAL & INSTALLATION
DISTRIBUTOR (DIGIFANT)
Removal (AFC-Digifant II)
Turn engine crankshaft to TDC. Remove distributor cap. Rotor
should point to No. 1 cylinder mark on edge of distributor housing.
Index mark the distributor housing to the crankcase relation. Remove
distributor hold-down clamp and bolt. Remove distributor assembly.
Installation
Align rotor with No. 1 cylinder mark on edge of distributor
housing. Install distributor and align housing to index mark made on
crankcase. Install distributor hold-down clamp and bolt. Install
distributor cap. Check timing. Tighten hold-down bolt to
specification. See TORQUE SPECIFICATIONS.
DISTRIBUTOR (CIS SYSTEMS)
Removal (CIS-E & CIS-E Motronic)
1) Turn engine crankshaft to TDC. Marking on vibration
dampener pulley must align with drive belt guard pointer. Marking on
cam shaft gear sprocket must align with cylinder head cover.
2) Remove distributor cap and mark position of rotor. Rotor
should be pointing to No. 1 cylinder in distributor firing sequence.
Mark position of distributor housing for installation reference.
Remove distributor hold-down clamp and bolt. Remove distributor
assembly, noting position of rotor when distributor shaft gear is
disengaged from driving gear.
Installation
1) Align oil pump drive pinion lug parallel to crankshaft.
Set rotor pointing toward mark made when distributor was disengaged
from drive gear.
2) Install distributor. Rotor should now point to mark made
for No. 1 cylinder in distributor firing sequence. Align mark for

N - REMOVE/INSTALL/OVERHAUL
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 09:49PM
distributor housing and install distributor hold-down clamp and bolt.
Install distributor cap. Check timing. Tighten hold-down bolt to
specification. See TORQUE SPECIFICATIONS.
AIRFLOW SENSOR PLATE
Removal & Installation
1) Remove air filter and unscrew stop bracket. Using heat
gun, heat locking compound on fastening bolt. Remove bolt slowly. DO
NOT damage threads. Clean locking compound from bolt hole threads.
2) Install airflow sensor plate. Ensure 5 dimple marks are
up. Lightly tighten self-locking screw. Ensure sensor plate is
centered and rest position is correct. To complete installation,
reverse removal procedure. See TORQUE SPECIFICATIONS.
AIRFLOW SENSOR POTENTIOMETER
Removal & Installation
Remove differential pressure regulator. Remove insulating
compound covering mounting screws. Remove potentiometer. DO NOT touch
or damage slide contact and conductor. To install, reverse removal
procedure. See TORQUE SPECIFICATIONS. Adjust potentiometer. See D -
ADJUSTMENTS article.
FUEL DISTRIBUTOR (1.8L ONLY)
CAUTION: Fuel system pressure must be relieved before removing or
disconnecting any fuel lines. Wipe up all spilled fuel
BEFORE continuing service.
Removal
1) Disconnect battery and remove air cleaner. Disconnect all
fuel and injector lines from fuel distributor. Plug fuel supply and
return lines. Catch any spilled fuel.
2) Disconnect wiring from differential pressure regulator.
Remove screws holding fuel distributor to airflow sensor housing.
Remove fuel distributor by turning back and forth while lifting up.
Air Sensor Plate Rest Position
Upper edge of sensor plate must be .070-080" (1.80-2.10 mm)
below lower edge of sensor cone. See Fig. 1. If rest position is
incorrect, raise sensor plate. Open or close wire clip to change
position of sensor plate. DO NOT bend leaf spring.Fig. 1: Identifying Sensor Plate Rest Position
Courtesy of Volkswagen United States, Inc.

N - REMOVE/INSTALL/OVERHAUL
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 09:49PM
distributor. Install fuel distributor. See TORQUE SPECIFICATIONS for
tightening specifications. Connect all fuel lines except those to fuel
injectors. Check sensor plate adjusting lever and fuel distributor
control piston for smooth operation.
2) Remove fuel pump relay and bridge fuel pump circuit. Use
Jumper Switch (US 4480/3) in place of fuel pump relay. When pressure
has built up, turn off fuel pump. Move sensor plate from rest position
to end of travel.
3) Uniform resistance should be felt during entire movement.
No resistance should be felt during entire movement. No resistance
should be felt on quick return to rest position. Connect injector
lines. Install fuel pump relay. Start engine and check for leaks.
INJECTORS (DIGIFANT)
CAUTION: Fuel system pressure must be relieved before removing
injectors. Wipe up all spilled fuel BEFORE continuing
service.
Removal (AFC-Digifant II)
Disconnect negative battery cable. Disconnect main electrical
connector from fuel rail. Remove idle stabilizer valve. Loosen and
remove both hoses on each end of fuel rail. Remove fuel pressure
regulator and mounting bracket. Remove fuel rail mounting bolts. Pry
off injector mounting clips. Disconnect injector electrical
connectors. Remove fuel rail. Remove each injector from its insert.
Installation
To install injectors, reverse removal procedures. Use new "O"
rings when installing injectors. Replace hose clamps if necessary. See
TORQUE SPECIFICATIONS table at end of this article. Check for fuel
leaks.
INJECTORS (CIS SYSTEMS)
Removal (CIS-E & CIS-E Motronic)
Remove injectors from inserts in cylinder head with fuel
lines attached. Using 12-mm or 13-mm hex wrench, remove inserts from
head. Use 2 wrenches to remove injectors from fuel lines.
Installation
To install, reverse removal procedures. Use 2 wrenches when
tightening injector lines to injectors. Use new "O" rings lightly
lubricated. On models with 2-piece inserts, replace insert sealing
washer (against head) and use sealing compound on upper insert
threaded portion. See TORQUE SPECIFICATIONS.
OXYGEN (O2) SENSOR
Removal & Installation
Oxygen (O2) sensor is mounted in the exhaust pipe in front of
catalytic converter. Disconnect permanent pigtail from sensor. Ensure

N - REMOVE/INSTALL/OVERHAUL
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 09:49PM
sensor is free of contaminants, avoid using any cleaning solvents.
Sensor may be difficult to remove when engine temperature is less than
118øF (48øC). Always use anti-seize compound on threads before
installation. Tighten sensor to specification. See
TORQUE SPECIFICATIONS.
SUPERCHARGER (CORRADO)
Removal & Installation
Information on removal and installation is not available from
manufacturer. See Fig. 4 for exploded view of supercharger assembly.Fig. 4: Supercharger Assembly Exploded View (Corrado)
Courtesy of Volkswagen United States, Inc.
THROTTLE VALVE HOUSING (TVH)
Removal & Installation
1) Disconnect accelerator cable from linkage. Disconnect
return spring on TVH. Remove cruise control connecting rod on TVH (if
equipped). Pull off vacuum hoses. Remove TVH mounting nuts.
2) Disconnect throttle valve switch. Remove 2 TVH-to-metallic
front vibration mounts nuts. Disconnect fuel return hose from pressure
regulator. Lift sensor housing upward and remove TVH. Remove gasket.
3) To install, reverse removal procedure. Ensure all surfaces
are clean and mate correctly. Use new gaskets when assembling. Adjust
accelerator linkage and idle speed. See TORQUE SPECIFICATIONS.
TORQUE SPECIFICATIONS

N - REMOVE/INSTALL/OVERHAUL
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 09:49PM
TORQUE SPECIFICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Ft. Lbs. (N.m)
AFC-Digifant II
Fuel Injector Inserts .................................... 15 (20)
Fuel Pressure Regulator Mounting Bolt .................... 11 (15)
Intercooler Bracket Mounting Bolts (Corrado) ............. 15 (20)
Knock Sensor ............................................. 15 (20)
Oxygen Sensor ............................................ 37 (50)
Supercharger Mounting Bolts (Corrado) .................... 18 (24)
Supercharger Pulley Bolt (Corrado) ....................... 33 (45)
Supercharger To Silencer Assembly Bolts (Corrado) ........ 18 (24)
Throttle Valve Body Mounting Bolts ....................... 15 (20)
CIS-E & CIS-E Motronic
Distributor Hold-Down Bolt (Fox) ......................... 18 (24)
Fuel Injection Valve Fuel Line Nut ....................... 18 (24)
Fuel Return Line Fitting ................................. 15 (20)
Fuel Supply Line Union Bolts ............................. 15 (20)
Intake Manifold Temperature Sensor (Jetta GLi 2.0L) ...... 15 (20)
Oxygen Sensor ............................................ 37 (50)
Thermo Time Switch (CIS-E) ............................... 22 (30)
Throttle Valve Housing Mounting Bolts .................... 15 (20)
INCH Lbs. (N.m)
AFC-Digifant II
Fuel Rail Mounting Bolts ................................. 87 (10)
Idle Stabilizer Valve Mounting Nuts ...................... 87 (10)
Intercooler Mounting Bolts (Corrado) ..................... 87 (10)
Supercharger Air Hose Mounting Bolts (Corrado) ........... 87 (10)
CIS-E & CIS-E Motronic
Auxiliary Air Regulator Mounting Bolts ................... 87 (10)
Cold Start Valve Mounting Bolts .......................... 87 (10)
Coolant Temperature Sensor ............................... 87 (10)
Distributor Hold-Down Bolt (Jetta GLi) ................... 87 (10)
EGR Valve Mounting Bolts ................................. 87 (10)
Fuel Distributor Mounting Bolts ......................... 30 (3.4)
Fuel Line Fittings ....................................... 87 (10)
Test Port Plug ........................................... 87 (10)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE

PRE-ALIGNMENT CHECKS
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:49PM
ARTICLE BEGINNING
Wheel Alignment
PRE-ALIGNMENT INSPECTION PROCEDURES
PRE-ALIGNMENT CHECKS
Before making wheel alignment adjustment, perform the
following checks:
1) Tires should be equal in size and runout must not be
excessive. Tires and wheels should be in balance, and inflated to
manufacturer's specifications.
2) Wheel bearings must be properly adjusted. Steering linkage
and suspension must not have excessive looseness. Check for wear in
tie rod ends and ball joints.
3) Steering gear box must not have excessive play. Check and
adjust to manufacturer's specifications.
4) Vehicle must be at curb height with full fuel load and
spare tire in vehicle. No extra load should be on vehicle.
5) Vehicle must be level with floor and with suspension
settled. Jounce front and rear of vehicle several times and allow it
to settle to normal curb height.
6) If steering wheel is not centered with front wheels in
straight-ahead position, correct by shortening one tie rod adjusting
sleeve and lengthening opposite sleeve equal amounts.
7) Ensure wheel lug nuts are tightened to torque
specifications.
END OF ARTICLE

SCHEDULED SERVICES
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:49PM
ARTICLE BEGINNING
1990-94 MAINTENANCE
Volkswagen Maintenance & Service Intervals
Corrado G60 (1990-92)
SLC (1992-94 USA)
VR6 (1992-94 Canada)
* PLEASE READ THIS FIRST *
NOTE: All SERVICE SCHEDULES are listed for normal service
vehicles. If vehicle is operated under severe service
conditions, see SEVERE SERVICE REQUIREMENTS (PERFORM
W/SERVICE SCHEDULES) for items requiring additional
maintenance.
NOTE: This article contains scheduled maintenance service
information. Fluid types and capacities listed with each
service in this article are only those necessary to perform
that scheduled service. For specifications pertaining to
fluid capacities for the entire vehicle, fuse and circuit
breaker identification, wheel and tire size, battery type,
warranty information, or model identification refer to the
MAINTENANCE INFORMATION article in this section.
CAUTIONS & WARNINGS
SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG) - 1995 MODELS
NOTE: See the AIR BAGS article in the ACCESSORIES/SAFETY EQUIPMENT
Section.
Modifications or improper maintenance, including incorrect
removal and installation of the Supplemental Restraint System (SRS),
can adversely affect system performance. DO NOT cover, obstruct or
change the steering wheel horn pad in any way, as such action could
cause improper function of the system. Use only plain water when
cleaning the horn pad. Solvents or cleaners could adversely affect the
air bag cover and cause improper deployment of the system.
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all warnings and service precautions. See
appropriate AIR BAGS article in ACCESSORIES/SAFETY EQUIPMENT.
CAUTION: Disconnect negative battery cable before servicing any air
bag system, steering column or passenger side dash
component. After any repair, turn ignition key to the ON
position from passenger's side of vehicle in case of
accidental air bag inflation