VOLKSWAGEN CORRADO 1990 Repair Manual

F - BASIC TESTING
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 09:44PM
ALL EXCEPT CORRADO & VANAGON
1) Remove fuel return line located near left strut tower.
Remove fuel tank cap. Attach a piece of hose between return line and a
1 qt. (.95 liter) graduated container.
2) Activate fuel pump for 30 seconds by removing fuel pump
relay and attaching jumper wire between terminals No. 30 and No. 87.
Remove fuel pump relay from fuse/relay block. Compare volume with
specifications.
CORRADO
1) Disconnect wire harness connector from fuel pump. See
Fig. 4. With voltmeter attached to terminals, activate fuel pump by
removing fuel pump relay and applying battery voltage to terminals No.
4 of the fuse box connection for the fuel pump relay. Fuel pump relay
located on fuse box housing. Terminal numbers are molded into fuse box
plastic housing.
2) Record voltage. Remove fuel line from outlet side of
accumulator. See Fig. 4. Attach a piece of hose between return line
and a graduated container. Activate fuel pump for 30 seconds. Compare
volume with specifications given in MAIN FUEL PUMP VOLUME (AFC-
Digifant II) table.
VANAGON
1) Remove the return line from the pressure regulator located
in engine compartment left side. Push a piece of hose onto open
connection of pressure regulator. Insert hose into a 1 qt. (1 liter)
graduated container.
2) Activate fuel pump for 30 seconds by removing fuel pump
relay and attaching jumper wire between terminals No. 30 and No. 87.
Fuel pump relay located left side of engine compartment in Black
plastic box. Compare volume with specifications.
FUEL PUMP PERFORMANCE TABLE (AFC-DIGIFANT II)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Pressure Min. Vol. in 30 Sec.
Application psi (kg/cm
ý) Pts. (L)
Cabriolet, Corrado,
Golf GL/GTI & Jetta .... 29-36 (2.0-2.5) ............... 1.0 (.5)
Vanagon ................. 33-39 (2.3-2.7) ............... 1.0 (.5)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄFUEL PUMP PERFORMANCE TABLE (CIS-E & CIS-MOTRONIC)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication @ Voltage Min. Vol. in 30 Sec. Pts. (L)
Fox
10 ........................................... .8 (.375)

F - BASIC TESTING
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 09:44PM
11 .......................................... 1.1 (.520)
12 .......................................... 1.4 (.675)
Jetta GLi
10 .......................................... 1.0 (.460)
11 .......................................... 1.3 (.620)
12 .......................................... 1.6 (.750)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄFig. 4: Identifying Main Fuel Pump (Fox & Jetta GLi)
Courtesy of Volkswagen United States, Inc.
IGNITION CHECKS (CIS-E)
NOTE: Ignition checks are divided according to fuel system.
SPARK TEST
1) Using an ohmmeter, check resistance of each spark plug
wire. See HIGH TENSION WIRE RESISTANCE table. Check for a strong Blue
spark at coil wire and each spark plug wire by holding wire terminal
5/16" ground while cranking engine.
2) Disconnect and inspect all related ignition system
connectors and harness. Clean or repair as necessary. If okay, remove
negative battery cable. Disconnect secondary lead from coil Remove
primary leads from ignition coil.
3) Using ohmmeter, check resistance between primary terminals
of coil. Check secondary resistance between coil secondary terminal
and primary positive terminal. Replace coil if readings are not within
specifications. See IGNITION COIL RESISTANCE table.
HIGH TENSION WIRE RESISTANCE TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Ohms

F - BASIC TESTING
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 09:44PM
Fox
Coil Wire With Connectors .................... 1600-2400
Spark Plug Wire With Connectors .............. 4800-7200
Spark Plug Connector ......................... 4000-6000
Suppressor .................................... 800-1200ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ IGNITION COIL RESISTANCE TABLE
IGNITION COIL RESISTANCE TABLE - Ohms @ 68
øF (20øC)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Primary Secondary
Jetta GLi 2.0L ......... .60-.70 ............. 6500-8500
All Other Models ....... .52-.76 ............. 2400-3500
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ DISTRIBUTOR
HALL EFFECT SENDER
1) Remove coil secondary and attach to ground. Disconnect
Hall Effect sender harness connector at distributor. Using a LED Test
Light (US 1115), check for voltage between outer terminals of
connector. See Fig. 5. With ignition on, light should be on. If not,
check wiring for short or open circuit. If wiring is okay, replace
Digifant control unit.
2) If light came on in step 1), reconnect Hall Effect sender
harness connector. Pull back Hall Effect sender boot to expose contact
terminals. Apply LED Test Light (US 1115) probe to center contact and
battery positive terminal. See Fig. 5. Observe test light while
cranking engine. If test light blinks, Hall Effect sender is okay. If
not, replace Hall Effect sender.Fig. 5: Testing Typical Hall Effect Sender
Courtesy of Volkswagen United States, Inc.
ELECTRONIC CONTROL UNIT (ECU)

F - BASIC TESTING
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 09:44PM
1) Perform SPARK TEST check. If secondary spark is present,
ignition control unit is okay. If not, turn ignition off. Disconnect
ignition control unit wire harness connector. Turn ignition on. Using
a voltmeter, measure voltage between terminal No. 2 (-) and terminal
No. 4 (+) of connector. See Fig. 6.
2) Voltage should be present. If not, ensure continuity
exists between terminal No. 2 and ground. Continuity must also exist
between terminal No. 4 and ignition coil positive terminal. Repair
wiring if necessary. If wiring is okay, replace ignition control unit.Fig. 6: Checking Typical Ignition Control Unit Voltage
Courtesy of Volkswagen United States, Inc.
NOTE: These tests require a high-impedance volt-ohmmeter.
IGNITION CHECKS (CIS-MOTRONIC)
SPARK
1) Using an ohmmeter, check resistance of each spark plug
wire. See HIGH TENSION WIRE RESISTANCE table. Check for a strong Blue
spark at coil wire and each spark plug wire by holding wire terminal
5/16" ground while cranking engine.
2) Disconnect and inspect all related ignition system
connectors and harness. Clean or repair as necessary. If okay, remove
negative battery cable. Disconnect secondary and primary leads from
ignition coil.
3) Using ohmmeter, check resistance between primary terminals
of coil. Check secondary resistance between coil secondary terminal
and primary positive terminal. Replace coil if readings are not within
specifications. See IGNITION COIL RESISTANCE table.
HIGH TENSION WIRE RESISTANCE TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Ohms
Jetta GLi
Coil Wire With Connectors .................... 1600-2400
Spark Plug Wire With Connectors .............. 4800-7200
Spark Plug Connector ......................... 4000-6000
Suppressor (1) ................................ 800-1200
(1) - Suppressor is located between ignition wire and

F - BASIC TESTING
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 09:44PM
distributor cap.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ HALL EFFECT SENDER & COIL POWER STAGE
The Hall Effect sender and coil power stage should be tested
if there is no spark at the spark plugs when tested. These tests also
check the CIS-Motronic ECU response to the Hall Effect sender signal.
Ensure SPARK and IGNITION COIL tests are performed first.
VOLTAGE SUPPLY & GROUND TO POWER STAGE
1) With ignition off, disconnect the coil power stage harness
connector. Connect a voltmeter to terminals No. 1 and No. 3. See
Fig. 7.
2) When ignition is turned on, there should be approximately
battery voltage. Turn ignition off. If there was no voltage, check for
an open wire from fuse box to terminal No. 1 or an open from terminal
No. 3 to ground. Repair open wire and recheck.Fig. 7: Testing Typical Ignition Coil Power Stage
Courtesy of Volkswagen United States, Inc.
VOLTAGE SUPPLY & GROUND TO HALL EFFECT SENDER
1) With ignition off, disconnect Hall Effect sender harness
connector. Using a voltmeter, check for voltage between outer
terminals No. 1 and No. 3. See Fig. 8. When ignition is turned on,
there should be a minimum of 9 volts.
2) If there is no voltage, check for open wire between
terminal No. 3 of the Hall Effect sender connector and terminal No. 30
of the ECU. Also check for voltage between terminal No. 1 of the Hall
Effect sender and ground. Repair open, and recheck.

F - BASIC TESTING
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 09:44PMFig. 8: Testing Typical Hall Effect Sender Connector
Courtesy of Volkswagen United States, Inc.
HALL EFFECT SENDER SWITCHING FUNCTION
1) Peel back the protective rubber boot on the Hall Effect
sender harness connector. Remove coil secondary and attach to ground.
Disconnect Hall Effect sender wire harness connector at distributor.
Using a LED Test Light (US 1115), check for voltage between outer
terminals of connector. See Fig. 5 or 8. With ignition on, light
should be on. If not, check wiring for short or open circuit. If not,
replace ignition control unit.
2) If light came on in step 1), reconnect Hall Effect sender
harness connector. Pull back Hall Effect sender boot to expose contact
terminals. Apply LED Test Light (US 1115) probe to center contact and
battery positive terminal. See Fig. 5 or 8. Observe test light while
cranking engine. If test light blinks, Hall Effect sender is okay. If
not, replace Hall Effect sender.
CIS-MOTRONIC (ECU) RESPONSE TO HALL EFFECT SENDER SIGNAL
1) Ground the ignition coil secondary lead. Remove coil
power stage connector and connect a LED test light (US 1115) between
terminals No. 2 and No. 3. See Fig. 7.
2) Actuate the starter, the test light should flicker. If
not, check for open wire between terminal No. 2 of the power stage
connector and terminal No. 11 of the ECU, or ECU is defective. Repair
wiring or replace ECU and recheck.
POWER STAGE RESPONSE TO CIS-MOTRONIC (ECU) SIGNAL
1) Reconnect the coil power stage connector, then disconnect
the Hall Effect sender connector and attach a voltmeter to terminal

F - BASIC TESTING
Article Text (p. 12)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:44PM
No. 1 and No. 15 of the coil.
2) Turn the ignition on, using a jumper wire, briefly connect
the center terminal of the Hall Effect sender connector to ground. The
voltage should briefly increase to at least 2 volts then drop to zero.
If not, either the ECU or coil power stage are defective.
IGNITION CHECKS (AFC-DIGIFANT II)
SPARK TEST
1) Using an ohmmeter, check resistance of each spark plug
wire. See HIGH TENSION WIRE RESISTANCE table. Check for a strong Blue
spark at coil wire and each spark plug wire by holding wire terminal
5/16" ground while cranking engine.
2) Disconnect and inspect all related ignition system
connectors and harness. Clean or repair as necessary. If okay, remove
negative battery cable. Disconnect secondary and primary leads from
ignition coil.
3) Using ohmmeter, check resistance between primary terminals
of coil. Check secondary resistance between coil secondary terminal
and primary positive terminal. Replace coil if readings are not within
specifications. See IGNITION COIL RESISTANCE table.
HIGH TENSION WIRE RESISTANCE TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Ohms
Vanagon
Coil Wire With Connectors ................... 1200-2800
Spark Plug Wire/Connector ................... 4600-7400
Spark Plug Connector ........................ 4000-6000
Suppressor (1) ............................... 600-1400
All Other Models
Coil Wire Only .................................... (1)
Coil Wire With Connector .................... 1600-2400
Spark Plug Wire/ Connector .................. 4000-6000
Suppressor (2) ............................... 600-1400
(1) - Check for continuity.
(2) - Suppressor is located between ignition wire and
distributor cap.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ IGNITION COIL
IGNITION COIL RESISTANCE TABLE - Ohms @ 68
øF (20øC)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Primary Secondary
Jetta GLi 2.0L ......... .60-.70 ............. 6900-8500
All Other Models ....... .52-.76 ............. 2400-3500
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

F - BASIC TESTING
Article Text (p. 13)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:44PM
DISTRIBUTOR
HALL EFFECT SENDER
1) Remove coil secondary and attach to ground. Disconnect
Hall Effect sender wire at the distributor. Using a LED Test Light (US
1115), check for voltage between outer terminals of connector. See
Fig. 5 or 8. With ignition on, light should be on. If not, check
wiring for short or open circuit. If wiring is okay, replace Digifant
control unit.
2) If light came on in step 1), reconnect Hall Effect sender
harness connector. Pull back Hall Effect sender boot to expose contact
terminals. Apply LED Test Light (US 1115) probe to center contact and
battery positive terminal. See Fig. 5. Observe test light while
cranking engine. If test light blinks, Hall Effect sender is okay. If
not, replace Hall Effect-sender.
IDLE SPEED, CO LEVEL & IGNITION TIMING
Ensure idle speed, CO level and base ignition timing are set
to specification. If necessary, see ON-VEHICLE ADJUSTMENTS article.
IDLE SPEED & CO LEVEL TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Idle RPM CO Level %
All Models ............ 800-1000 .............. 0.3-1.2%
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄIGNITION TIMING TABLE (Degrees BTDC @ RPM)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Checking Adjusting
1.8L ............... 4-8 @ 2250-2350 . 5-7 @ 2250-2350
2.0L ................ 4-8 @ 770-830 ...... 5-7 @ 770-830
2.1L (1) ........... 4-8 @ 2250-2350 . 5-7 @ 2250-2350
(1) - With coolant temperature sensor disconnected.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ SUMMARY
If no faults were found while performing F - BASIC TESTING,
proceed to H - TESTS W/CODES article for diagnosis by symptom (i.e.,
ROUGH IDLE, NO START, etc.) or intermittent diagnostic procedures.
END OF ARTICLE

FUEL HOSE MAY SHRINK & LEAK CAUSING FIRE: NEW CLAMP
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:45PM
ARTICLE BEGINNING
NHTSA RECALL BULLETIN
Model(s): 1988 Volkswagen Golf
1988 Volkswagen Jetta
1989 Volkswagen Golf
1989 Volkswagen Jetta
1990 Volkswagen Corrado
1990 Volkswagen Fox
1990 Volkswagen Golf
1990 Volkswagen Jetta
1990 Volkswagen Vanagon
1991 Volkswagen Corrado
1991 Volkswagen Fox
1991 Volkswagen Golf
1991 Volkswagen Jetta
1991 Volkswagen Vanagon
1992 Volkswagen Corrado
1992 Volkswagen Fox
1992 Volkswagen Golf
1992 Volkswagen Jetta
Campaign No: 92V058001
Number of Affected Vehicles: 340000
Beginning Date of Manufacture: 1985 JUL
Ending Date of Manufacture: 1992 JUN
VEHICLE DESCRIPTION:
Passenger cars.
DESCRIPTION OF DEFECT:
The fuel hose attached to the fuel distribution rail on the engine may
shrink beyond the clamp force of the fuel hose clamps, allowing fuel
to leak.
FAULT:
Poor fit/loose
SYSTEM:
Fuel lines.
CONSEQUENCE OF DEFECT:
Fuel leakage in the engine compartment can cause an underhood fire if
the fuel comes in contact with a source of ignition.
CORRECTIVE ACTION:

FUEL HOSE MAY SHRINK & LEAK CAUSING FIRE: NEW CLAMP
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 09:45PM
Replace the fuel hose attached to the fuel rail and install a new
spring type self-tightening clamp.
NOTE:
Volkswagen of America estimates the new self-tightening fuel hose
clamps will be available in May of 1992.
this is a supplemental report. All new data has been added to NHTSA
campaign number 92V058000.
ADDITIONAL INFORMATION:
The National Highway Traffic Safety Administration operates Monday
through Friday from 8:00 AM to 4:00 PM, Eastern Time. For more
information call (800) 424-9393 or (202) 366-0123. For the hearing
impaired, call (800) 424-9153.
END OF ARTICLE