VOLKSWAGEN CORRADO 1990 Repair Manual

FUEL LEAKAGE COULD CAUSE FIRE:NEW FUEL HOSE & CLAMPS
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 Cabriolet
1990 Volkswagen Corrado
1990 Volkswagen Fox
1990 Volkswagen Golf
1990 Volkswagen Jetta
1990 Volkswagen Vanagon
1991 Volkswagen Cabriolet
1991 Volkswagen Corrado
1991 Volkswagen Fox
1991 Volkswagen Golf
1991 Volkswagen Jetta
1991 Volkswagen Vanagon
1992 Volkswagen Cabriolet
1992 Volkswagen Corrado
1992 Volkswagen Fox
1992 Volkswagen Golf
1992 Volkswagen Jetta
1993 Volkswagen Fox
1993 Volkswagen Passat
Campaign No: 92V058000
Number of Affected Vehicles: 358000
Beginning Date of Manufacture: 1985 JUL
Ending Date of Manufacture: 1992 JUN
VEHICLE DESCRIPTION:
Passenger cars.
SYSTEM:
Fuel lines.
FAULT:
Poor, loose fit.
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.
CONSEQUENCE OF DEFECT:

FUEL LEAKAGE COULD CAUSE FIRE:NEW FUEL HOSE & CLAMPS
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
Fuel leakage in the engine compartment can cause an underhood fire if
the fuel comes in contact with a source of ignition.
CORRECTIVE ACTION:
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. Supplement 92V058001
information had been added to this campaign.
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

FUSES & CIRCUIT BREAKERS
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
1990-94 ELECTRICAL
Volkswagen Fuses & Circuit Breakers
Corrado
FUSES & CIRCUIT BREAKERS
FUSE PANEL LOCATION
Fuse panel is located under left side of dash board by
driver's knee. Fuses are numbered from left to right.
FUSE PANEL IDENTIFICATION
NOTE: Four separate 30 amp fuses for power windows, air
conditioning, ABS main relay and ABS hydraulic pump relay are
placed above fuse panel.Fig. 1: Fuse Panel Identification
Courtesy of Volkswagen United States, Inc.
WARNING: Always disconnect battery ground cable before servicing
"high-current fuses. It is recommended that "high-current"
fuses be replaced by a qualified technician.
Fuse & Circuit Breaker Identification
1 - 10 Amp
Left Low Beam
2 - 10 Amp
Right Low Beam
3 - 10 Amp
Instrument Lights, License Plate Lights
4 - 15 Amp
Rear Window Wiper, Sliding Roof
5 - 15 Amp
Windshield & Rear Window Washer, Windshield Wiper
6 - 20 Amp
Air Conditioner, Fresh Air Fan
7 - 10 Amp

FUSES & CIRCUIT BREAKERS
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
Right Tail & Side Lights
8 - 10 Amp
Left Tail & Side Lights
9 - 20 Amp
Rear Window & Mirror Heating
10 - 15 Amp
Foglights
11 - 10 Amp
Left High Beam, High Beam Indicator
12 - 10 Amp
Right High Beam
13 - 10 Amp
Horn, Radiator Fan
14 - 15 Amp
Back-Up Lights, Electric Mirrors, Heated Windshield Washer
Jets
15 - 10 Amp
Engine Electronic
16 - 15 Amp
Warning/Indicator Lights, Multi-Function Indicator, Glove Box
Light, Cassette Storage Light, Rear Spoiler
17 - 10 Amp
Turn Signals
18 - 20 Amp
Fuel Pump, Oxygen Sensor
19 - 30 Amp
Radiator Fan, Air Conditioner
20 - 10 Amp
Brakelights, Cruise Control
21 - 15 Amp
Dome & Luggage Compartment Lights, Cigarette Lighter, Central
Locking System, Multi-Function Indicator
22 - 10 Amp
Radio
CAUTIONS & WARNINGS
ELECTRICAL SHOCK
WARNING: Contact with live components of ignition system while
engine is running could lead to a fatal electric shock.
RADIATOR FAN
Keep hands away from radiator fan. Fan is controlled by a
thermostatic switch which may come on or run for up to 15 minutes even
after engine is turned off.
RADIATOR CAP
CAUTION: Always disconnect the fan motor when working near the
radiator fan. The fan is temperature controlled and could

FUSES & CIRCUIT BREAKERS
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 09:45PM
start at any time even when the ignition key is in the OFF
position. DO NOT loosen or remove radiator cap when cooling
system is hot.
REPLACING BLOWN FUSES
Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical system. Be
sure to use fuse with the correct indicated amperage rating. The use
of an incorrect amperage rating fuse may result in a dangerous
electrical system overload.
BATTERY WARNING
WARNING: 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 GENERAL INFORMATION section.
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning
that brake pads need replacement.
HALOGEN BULBS
Halogen bulbs contain pressurized gas which may explode if
overheated. DO NOT touch glass portion of bulb with bare hands. Eye
protection should be worn when handling or working around halogen
bulbs.
SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)
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

FUSES & CIRCUIT BREAKERS
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 09:45PM
position from passenger's side of vehicle in case of
accidental air bag inflation
ANTI-LOCK BRAKE SYSTEM
The anti-lock brake system contains electronic equipment that
can be susceptible to interference caused by improperly installed or
high output radio transmitting equipment. Since this interference
could cause the possible loss of the anti-lock braking capability,
such equipment should be installed by qualified professionals.
CATALYTIC CONVERTER
To prevent catalytic converter overheating, DO NOT allow
engine to idle for more than 20 minutes.
END OF ARTICLE

G - TESTS W/CODES
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
1990 ENGINE PERFORMANCE
VW Self-Diagnostics
Corrado
DIGIFANT II SYSTEM TROUBLESHOOTING
ENGINE CODE PG applying to:
* 49 State and Canada, model years 1989 to present.
* California vehicles model years 1989 and 1990
NOTE: These vehicles do not have On Board Diagnostic capability. It
is not possible to read a DTC memory on these vehicles
regardless of method. This includes using the VAG 1551 Scan
Tool and the VGA 1527B LED tester.
CAUTION: A brown data link connector has been installed in the center
console of some vehicles. Do not connect the VAG 1551 Scan
Tool to this connector; it is not intended for use outside of
the factory. When accessed, the codes that it provides will
indicate faulty components in cases where this is not true.
END OF ARTICLE

GEAR TOOTH CONTACT PATTERNS
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
GENERAL INFORMATION
Gear Tooth Contact Patterns
* PLEASE READ THIS FIRST *
The following article is for GENERAL INFORMATION purposes
only. Information does not SPECIFICALLY apply to all years, makes and
models, but is to be used as a general reference guide.
INSPECTION
PRELIMINARY INSPECTION
Wipe lubricant from internal parts. Rotate gears and inspect
for wear or damage. Mount dial indicator to housing, and check
backlash at several points around ring gear. Backlash must be within
specifications at all points. If no defects are found, check gear
tooth contact pattern.
GEAR TOOTH CONTACT PATTERN
NOTE: Drive pattern should be well centered on ring gear teeth.
Coast pattern should be centered, but may be slightly toward
toe of ring gear teeth.
1) Paint ring gear teeth with marking compound. Wrap cloth or
rope around drive pinion flange to act as brake. Rotate ring gear
until clear tooth contact pattern is obtained.
2) Contact pattern will indicate whether correct pinion
bearing mounting shim has been installed and if drive gear backlash
has been set properly. Backlash between drive gear and pinion must be
maintained within specified limits, until correct tooth pattern is
obtained.

GEAR TOOTH CONTACT PATTERNS
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 09:45PMFig. 1: Drive Axle Gear Tooth Patterns
ADJUSTMENTS
GEAR BACKLASH & PINION SHIM CHANGES
NOTE: Backlash is adjusted by either moving shims from one side of
differential case to the other or by turning adjusting nuts
on which side bearing races ride. Changing of pinion shims
alters the distance from face of pinion of centerline of
ring gear.
1) With no change in backlash, moving pinion further from
ring gear moves drive pattern toward heel and top of tooth, and moves
coast pattern toward toe and top of tooth.
2) With no change in backlash, moving pinion closer to ring
gear moves drive pattern toward toe and bottom of tooth, and moves
coast pattern toward heel and bottom of tooth.
3) With no change in pinion shim thickness, an increase in
backlash moves ring gear further from pinion. Drive pattern moves
toward heel and top of tooth, and coast pattern moves toward heel and
top of tooth.

GEAR TOOTH CONTACT PATTERNS
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 09:45PM
4) With no change in pinion shim thickness, decrease in
backlash moves ring gear closer to pinion gear. Drive pattern moves
toward toe and bottom of tooth, and coast pattern moves toward toe and
bottom of tooth.
END OF ARTICLE