technical specifications VOLKSWAGEN CORRADO 1990 Repair Manual

SUSPENSION - FRONT
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 09:51PM
NOTE: Wheel bearing is destroyed when pressed out of housing. When
either wheel hub or bearing has been removed from housing, a
new bearing must be installed.
Removal
1) Remove axle shaft nut. Raise and support vehicle with
safety stands. Allow suspension to hang free. Remove wheel assembly.
Remove brake caliper attaching bolts. Remove caliper and hang out of
work area. Remove brake disc retaining screw and remove disc.
2) Remove tie rod ball joint from wheel bearing housing.
Remove nut and clamp bolt from control arm ball joint. Remove control
arm ball joint from wheel bearing housing and remove housing.
3) Remove 2 circlips retaining bearing in hub. Using Hub
Remover (VW 295a), press wheel hub from bearing housing. Using a
bearing puller, remove wheel bearing inner race from hub assembly.
Using Bearing Remover (VW 433), press wheel bearing from outboard end
of bearing housing.
Installation
1) Press new bearing race onto hub. Using Bearing & Hub
Installer (VW 472/1), press new bearing into bearing housing from
outboard side. Using same adapter, press wheel hub into bearing
housing. Apply a small bead of locking compound to axle splines before
installing into hub.
2) To complete installation, reverse removal procedure.
Always replace self-locking axle shaft nut. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS TABLE at end of article.
Check wheel alignment. See SPECIFICATIONS & PROCEDURES article in the
WHEEL ALIGNMENT Section.
NOTE: When installing hub, ensure press adapter contacts inner
bearing race only.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Ft. Lbs. (N.m)
Axle Nut ............................................ 170 (230)
Axle Shaft-To-Transaxle Bolt .......................... 32 (43)
Ball Joint Clamp Bolt ................................. 37 (50)
Ball Joint-To-Control Arm Bolt ........................ 18 (24)
Caliper Pin Bolt ...................................... 18 (24)
Control Arm Pivot Bolt
Cabriolet ........................................... 50 (68)
All Others ......................................... 96 (130)
Control Arm-To-Subframe Rear Bushing Bolt ............ 96 (130)
Strut Piston Rod Nut
Cabriolet ........................................... 50 (68)
All Others .......................................... 44 (60)

SUSPENSION - REAR
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:51PM
ARTICLE BEGINNING
1990-92 SUSPENSION
Volkswagen Rear
Cabriolet, Corrado, Fox,
Golf, GTI, Jetta, Passat
DESCRIPTION
Rear suspension is link type with MacPherson suspension
struts. Suspension uses control arms and axle beam for stabilization.
Control arms and axle beam are combined as one unit. Brake drums or
discs rotate on stub axles bolted to control arms. See Fig. 1.Fig. 1: Identifying Rear Suspension Components (Typical)
Courtesy of Volkswagen United States, Inc.
ADJUSTMENTS & INSPECTION
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
NOTE: See SPECIFICATIONS & PROCEDURES article in the WHEEL
ALIGNMENT Section.
WHEEL BEARING
Tighten hub nut to 7.5 ft. lbs. (10 N.m) while rotating brake

SUSPENSION - REAR
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 09:51PM
NOTE: DO NOT remove both suspension struts at same time, as this
would overload axle beam bushings.
Removal
1) With vehicle on floor, remove plastic cap which covers
upper strut retaining nuts. Remove strut retaining nuts. Slowly raise
vehicle until weight is off spring. Remove bolt which retains lower
end of strut shock absorber to axle beam mount. Raise vehicle until
strut can be removed. Place strut assembly in vise.
2) Hold piston rod. Remove strut retaining nut and related
components. See Fig. 1. Remove slotted nut (some models). Remove
spacer and coil spring. If coil spring is to be replaced, ensure paint
stripe color on replacement spring matches original spring color
stripe.
Installation
1) Install protective cap and tube onto shock absorber.
Install rubber buffer with small end downward. Install snap ring and
washer. Place spring into lower seat. Install upper retainer with
spacer sleeve.
2) Tighten slotted nut (some models) which retains piston
rod. Install upper mounting hardware. Tighten piston rod. To complete
installation, reverse removal procedure. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS TABLE at end of article.
SUSPENSION ASSEMBLY
CAUTION: When removing suspension assembly, add weight to rear of
vehicle to prevent tipping resulting from change in center
of gravity.
Removal
1) With vehicle on floor, disconnect upper strut mount. Raise
and support vehicle. Disconnect parking brake at bracket near axle
mount.
2) Disconnect and plug brake lines. Leave flex hose attached
to suspension. Separate brake pressure regulator spring from axle beam
(if equipped). Remove nuts which retain axle beam to body.
NOTE: DO NOT install bolts and nuts fouled with undercoating. With
waxy coating on threads, true tightening torque cannot be
measured. Clean or replace bolts and nuts.
Installation
1) If axle beam mounting has been removed, adjust mounting
pad. See Fig. 2. If pad is not correctly aligned, torsional preload of
mounting bushings will be incorrect.
2) Position rear suspension on body. Install nuts retaining
axle beam to body. Raise wheel. Guide upper end of strut into body
mount.
3) Connect parking brake cables. Connect brake lines. Lower

SUSPENSION - REAR
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 09:51PM
vehicle. Tighten upper strut retaining nuts. Tighten all bolts and
nuts to specification. Bleed brake system.
WHEEL BEARING
Removal (Disc Brakes)
Raise and support vehicle. Remove wheel assembly. Remove
caliper assembly and support it out of work area. Remove dust cap,
cotter pin, hub nut, and thrust washer. Remove brake disc. Using a
long drift, tap bearings, races, and grease seal from disc hub.
Installation
1) Clean hub cavity thoroughly. Using Bearing Race Installer
(VW 432 and VW 411), press inner and outer bearing races into bore.
Lubricate and install inner bearing. Using Seal Installer (VW 295 and
3074), tap grease seal into bore.
2) Install brake disc, outer bearing, thrust washer, and hub
nut. Reverse removal procedure to complete installation. Adjust wheel
bearing. See WHEEL BEARING under ADJUSTMENTS & INSPECTION. Install NEW
cotter pin.
Removal (Drum Brakes)
Raise and support vehicle. Remove wheel assembly. Remove dust
cap, cotter pin, hub nut, and thrust washer. Remove brake drum. Using
a long drift, tap bearings, races, and grease seal from hub.
Installation
1) Clean hub cavity thoroughly. Using Outer Bearing Race
Installer (VW 431 and VW 411), press outer bearing race into bore.
Using Inner Bearing Race Installer (VW 432 and VW 411), press inner
bearing race into bore. Lubricate and install inner bearing. Using
Seal Installer (VW 295 and 3074), tap grease seal into bore.
2) Install brake drum, outer bearing, thrust washer, and hub
nut. Reverse removal procedure to complete installation. Adjust wheel
bearing. See WHEEL BEARING under ADJUSTMENTS & INSPECTION. Install NEW
cotter pin.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Ft. Lbs. (N.m)
Brake Caliper Bolt .................................... 48 (65)
Coil Spring Retainer-To-Piston Rod Nut ................ 11 (15)
Rear Axle Beam Pivot Bushing Bolt ..................... 43 (58)
Rear Axle Mounting Pad-To-Body Bolt ................... 63 (85)
Shock Absorber Slot Nut ............................... 15 (20)
Shock Absorber-To-Axle Beam Nut ....................... 52 (70)
Shock Absorber-To-Body Bolt ........................... 26 (35)
Stub Axle-To-Control Arm Bolt ......................... 44 (60)
Wheel Lug Bolt ....................................... 81 (110)

TRANSMISSION REMOVAL & INSTALLATION - A/T
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 09:51PM
bolts on front mount and remove mount. Place mating marks on drive
axle flanges and remove left and right axle shaft flange bolts.
4) Disconnect right strut-to-spindle bolts. Remove right side
axle. Reconnect strut. Remove protective plate from transaxle. Remove
torque converter-to-drive plate bolts.
5) Slightly lower engine assembly. Support transaxle with
jack. Remove lower transaxle-to-engine mounting bolts. Lower
transaxle. To install, reverse removal procedure. Adjust accelerator
and selector cables.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplications Ft. Lbs. (N.m)
Cabriolet, Golf, GTI & Jetta
Axle Shaft-To-Flange Bolts ................ 33 (45)
Torque Converter-To-Drive Plate Bolts ..... 26 (35)
Transaxle-To-Engine Bolts ................. 55 (75)
Corrado & Passat
Axle Shaft Nut .......................... 195 (265)
Axle Shaft-To-Flange Bolts ................ 33 (45)
Strut-To-Spindle .......................... 70 (95)
Torque Converter-To-Drive Plate Bolts ..... 45 (60)
Transaxle-To-Engine
M10 Bolts ............................... 45 (60)
M12 Bolts ............................... 60 (80)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE

TROUBLE SHOOTING - BASIC PROCEDURES
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 09:52PM
Parallelism not to
specifications Reface or replace rotor
Wheel bearings not adjusted See SUSPENSION
Rear drums out-of-round Reface or replace drums
Disc pad reversed, steel
against rotor Remove and reinstall
padÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄExcessive Pedal
Effort Malfunctioning power unit See POWER BRAKES or
BRAKE SYSTEM
Partial system failure Check fluid and pipes
Worn disc pad or lining Replace pad or lining
Caliper piston stuck or
sluggish See DISC BRAKES or
BRAKE SYSTEM
Master cylinder piston
stuck See MASTER CYLINDERS
or BRAKE SYSTEM
Brake fade due to incorrect
pads for linings Replace pads or linings
Linings or pads glazed Replace pads or linings
Worn drums Reface or replace drums
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄExcessive Pedal
Travel Partial brake system failure Check fluid and pipes
Insufficient fluid in
master cylinder See MASTER CYLINDERS or
BRAKE SYSTEM
Air trapped in system See BRAKE BLEEDING or
BRAKE SYSTEM
Rear brakes not adjusted See Adjustments in DRUM
BRAKES or BRAKE SYSTEM
Bent shoe or lining See DRUM BRAKES or
BRAKE SYSTEM
Plugged master cylinder cap See MASTER CYLINDERS
or BRAKE SYSTEM

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:53PM
ARTICLE BEGINNING
1990-91 WHEEL ALIGNMENT
Specifications & Procedures
1990-91 Passat
1991 Cabriolet, Corrado, Fox, Golf, GTI, Jetta, Vanagon
PRE-ALIGNMENT INSTRUCTIONS
NOTE: Prior to performing wheel alignment, perform preliminary
visual and mechanical inspection of wheels, tires and
suspension components. See ALIGNMENT THEORY/OPERATION in
the WHEEL ALIGNMENT Section.
RIDING HEIGHT ADJUSTMENT
NOTE: On vehicles with electronic chassis controls, all systems
should be functional before attempting riding height or
wheel alignment adjustment.
Before adjusting alignment, ensure difference in riding
height between left and right sides of vehicle is less than 1" (25.4
mm). Riding height must be checked with vehicle on level floor and
tires properly inflated. Bounce vehicle several times and allow
suspension to settle.
Visually inspect vehicle for signs of abnormal height from
front to rear or side to side. Check passenger and luggage
compartments for extra heavy items and remove if present. If
difference in riding height between left and right sides of vehicle is
NOT less than 1" (25.4 mm), check suspension components and repair or
replace as necessary.
WHEEL ALIGNMENT SPECIFICATIONS
WHEEL ALIGNMENT SPECIFICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Preferred Range
Cabriolet
Camber (1)
Front ................ 5/16 ............... -3/16 To 13/16
Rear ................ -1 1/4 .......... -1 13/16 To -11/16
Caster (1) ........... 1 3/16 ............ 1 5/16 To 2 5/16
Toe-In (2)
Front .......... -1/8 (-3) .. -3/16 To -1/16 (-4.5 To-1.5)
Rear ............ 5/32 (4) ........ 1/32 To 9/32 (1 To 7)
Toe-In (1)
Front ................ -1/4 ................. -3/8 To -1/8
Rear ................. 5/16 ................. 1/16 To 9/16
Toe-Out On Turns (1)

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
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 09:53PM
Inner ................. 20 ......................... .....
Outer ............... 18 1/2 ....................... .....
Corrado
Camber (1)
Front ............... -21/32 ................. -1 To -5/16
Rear ................. -1/2 ........ -1 21/32 To -1 11/32
Caster (1) ........... 1 19/32 ........... 1 3/32 To 2 3/32
Toe-In (2)
Front ................ 0 (0) . -3/32 To 3/32 (-2.5 To 6.5)
Rear .............. 5/32 (4) .... 1/16 To 1/4 (1.5 To 6.5)
Toe-In (1)
Front .................. 0 ................. -5/32 To 5/32
Rear ................. 11/32 ................. 3/16 To 1/2
Fox (Except Wagon)
Camber (1)
Front ................ -1/2 .............. -13/16 To -3/16
Rear ................ -1 1/2 .................... -2 To -1
Caster (1) .............. 2 ............. 1 11/16 To 2 5/16
Toe-In (2)
Front ............. -1/16 (-1.5) ...... -1/8 To 0 (-3 To 0)
Rear .............. 7/32 (5.5) ..... 1/8 To 9/32 (3 To 7)
Toe-In (1)
Front ................. -1/8 .................... -1/4 To 0
Rear ................. 7/16 .................. 1/4 To 9/16
Fox Wagon
Camber (1)
Front ................ -1/2 ............... -13/16 To 3/16
Rear ................ -1 1/2 ..................... -2 To 1
Caster (1) ............ 1 3/4 ............ 1 7/16 To 2 1/16
Toe-In (2)
Front ............ -1/16 (-1.5) ...... -1/8 To 0 (-3 To 0)
Rear ............ 5/32 (4) ...... 1/16 To 1/4 (1.5 To 6.5)
Toe-In (1)
Front ................ -1/8 .................... -1/4 To 0
Rear ................. 5/16 ................... 1/8 To 1/2
Golf & Jetta
(Except GLi)
Camber (1)
Front ................ -7/16 ................ -3/4 To -1/8
Rear ............... -1 11/16 ............... -2 To -1 3/8
Caster (1) ............ 1 1/2 ...................... 1 To 2
Toe-In (2)
Front ................ 0 (0) . -1/16 To 1/16 (-1.5 To 1.5)
Rear ............. 7/32 (5.5) ....... 1/8 To 5/16 (3 To 8)
Toe-In (1)
Front .................. 0 ................... -1/8 To 1/8
Rear ................. 7/16 ................... 1/4 To 5/8
GTI & Jetta GLi
Camber (1)
Front ................ -9/16 ................ -7/8 To -1/4
Rear ............... -1 11/16 ............... -2 To -1 3/8
Caster (1) ........... 1 9/16 ............ 1 1/16 To 2 1/16

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
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 09:53PM
Toe-In (2)
Front ................ 0 (0) . -1/16 To 1/16 (-1.5 To 1.5)
Rear ............. 7/32 (5.5) ....... 1/8 To 5/16 (3 To 8)
Toe-In (1)
Front .................. 0 ................... -1/8 To 1/8
Rear ................. 7/16 ................... 1/4 To 5/8
Passat
Camber (1)
Front .............. -1 11/32 ............. -1 11/16 To -1
Rear ............... -1 21/32 .............. -2 To -1 5/16
Caster (1) ........... 1 21/32 ........... 1 5/32 To 2 5/32
Toe-In (2)
Front ................. 0 (0) -3/32 To 3/32 (-2.5 To 2.5)
Rear ............ 7/32 (5.5) ... 3/32 To 11/32 (2.5 To 8.5)
Toe-In (1)
Front .................. 0 ................. -5/32 To 5/32
Rear ................. 13/32 ............... 5/32 To 21/32
Toe-Out On Turns (1) .... N/A ...............................
Vanagon (Except Syncro)
Camber (1)
Front .................. 0 ................... -1/2 To 1/2
Rear ................ -13/16 ............. -1 5/16 To 5/16
Caster (1) ............ 7 1/4 .................. 7 To 7 1/2
Toe-In (2)
Front .............. 5/32 (4) ...... 1/32 To 9/32 (1 To 7)
Rear ................ 0 (0) ....... -5/32 To 5/32 (-4 To 4)
Toe-In (1)
Front ................ 5/16 ................. 1/16 To 9/16
Rear ................... 0 ................. -5/16 To 5/16
Vanagon (Syncro)
Camber (1)
Front ................ 5/16 ..................... 0 To 5/8
Rear ................. -1/4 ............... -7/16 To -1/16
Caster (1) ............ 4 5/8 .............. 4 3/8 To 4 7/8
Toe-In (2)
Front ................ 0 (0) ....... -1/8 To 1/8 (-3 To 3)
Rear ........... 1/16 (1.5) ... -1/16 To 3/16 (-1.5 To 4.5)
Toe-In (1)
Front .................. 0 ................... -1/4 To 1/4
Rear .................. 1/8 .................. -1/8 To 3/8
(1) - Measurement in degrees.
(2) - Measurement in inches (mm).ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE

WHEEL ALIGNMENT THEORY/OPERATION
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:53PM
ARTICLE BEGINNING
GENERAL INFORMATION
Wheel Alignment Theory & Operation
ALL MODELS
* PLEASE READ THIS FIRST *
NOTE: This article is intended for general information purposes
only. This information may not apply to all makes and models.
PRE-ALIGNMENT INSTRUCTIONS
GENERAL ALIGNMENT CHECKS
Before adjusting wheel alignment, check the following:
* Each axle uses tires of same construction and tread style,
equal in tread wear and overall diameter. Verify that radial
and axial runout is not excessive. Inflation should be at
manufacturer's specifications.
* Steering linkage and suspension must not have excessive play.
Check for wear in tie rod ends and ball joints. Springs must
not be sagging. Control arm and strut rod bushings must not
have excessive play. See Fig. 1.Fig. 1: Checking Steering Linkage
* Vehicle must be on level floor with full fuel tank, no
passenger load, spare tire in place and no load in trunk.
Bounce front and rear end of vehicle several times. Confirm
vehicle is at normal riding height.