engine VOLKSWAGEN CORRADO 1990 Workshop Manual

* SUSPENSION UNIFORM INSPECTION GUIDELINES *
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 09:38PM
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
concerned with auto repair and/or consumer protection are conducted.
Feedback from these representatives are brought back to members, and
the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers arbitration through MAP/BBB-CARE in cooperation with the
Council of Better Business Bureaus and individual participating
Bureaus. MAP "piloted" in Indianapolis and Pittsburgh during spring,
1996 - and publicized "roll-outs" in New Jersey, Detroit (MI), Chicago
(IL) and Richmond (VA) were conducted. To put some "teeth" in the
program, and accreditation requirement for shops was initiated. The
requirements are stringent and a self-policing method has been
incorporated which includes the "mystery shopping" of outlets. In
addition, a committee of service providers had been working diligently
developing standards for newspaper, television and Internet
advertising.
We welcome you to join us as we continue our outreach ...
with your support, both the automotive repair industry and your
customers will reap the benefits. Please visit MAP at our Internet
site: www.hunter.com/map.htm or contact us at:
808 17th Street, NW Suite 200
Washington, D.C. 20006
Ph. (202) 466-7050 Fax (202) 223-9569
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
It is MAP policy that all exhaust, brake, ABS, steering and
suspension, wheel alignment, tires and wheels, driveline, engine
performance and maintenance and heating, ventilation and air
conditioning services be offered and performed under the guidelines
and procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be required or suggested.
In addition, suggestions may be made to satisfy the needs expressed by
the customer.
This section lists the various parts and conditions that
indicate required or suggested service or part replacement. Although
this list is extensive, it is not inclusive. In addition to this list,
a technician may make a suggestion. This suggestion must be based on
substantial and informed experience or the vehicle manufacturer's
recommended service interval.

* SYMPTOM CHECK LIST *
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 09:40PM
NOTE: Have the service adviser fill out these forms with the
customer whenever possible.Fig. 6: Engine Driveability & Automatic Transmission

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:40PM
ARTICLE BEGINNING
1989-90 VOLKSWAGEN ENGINES
1.8L 8-Valve & 1.8L 16-Valve 4-Cylinder
1989-90
Cabriolet, Fox, Golf, GTI, Jetta, Jetta GLI
1990
Corrado
* PLEASE READ THIS FIRST *
NOTE: For engine repair procedures not covered in this article,
see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article
in the GENERAL INFORMATION section.
ENGINE IDENTIFICATION
Engine identification number is stamped on a machined pad,
left side of engine block, near distributor assembly. See Fig. 1. The
first 2 characters designate engine code.
ENGINE IDENTIFICATION CODES TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Engine Code
1.8L 8-Valve 4-Cylinder
Cabriolet ........................................ JH
Fox .............................................. UM
Golf, Golf GT & Jetta ............... (1) GX, RV or PF
1.8L 16-Valve 4-Cylinder
GTI & Jetta GLI .................................. PL
(1) - Code GX is a 1.8L with 85 HP. Code RV is a 1.8L
with 100 HP. Code PF is a 1.8L with 105 HP.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄFig. 1: Engine Identification Number Location
Courtesy of Volkswagen United States, Inc.

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
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 09:40PM
NOTE: Match mark engine mounts to ensure original alignment is
achieved after installation. On vehicles with A/C and power
steering, remove components with hoses attached and secure
out of way.
ENGINE R & I (EXCEPT FOX)
REMOVAL (EXCEPT FOX)
1) Disconnect and remove battery. Open fuel tank fill cap and
radiator cap. Remove intake air duct. On 16-valve engines, remove
intake manifold assembly. On vehicles with A/C, remove trim panel and
lower apron. Remove condenser from crossmember and radiator. Remove
all duct work. Mark and disconnect A/C and cooling fan electrical
connectors. Remove accessory belts.
2) On Golf, GTI and Jetta models, leave A/C hoses attached
and remove A/C compressor. Pivot A/C condenser and compressor to side
of vehicle and secure.
3) On Cabriolet and Scirocco models, remove alternator and
timing belt cover. Remove 3 A/C bracket Allen head bolts behind timing
belt cover. Remove A/C bracket support brace. Remove A/C compressor
bracket bolts. Leave hoses attached and secure A/C compressor with
bracket out of way.
4) On all models, open heater controls. Remove cooling hose
from thermostat housing flange and drain coolant. Remove flange. Mark
and remove all cooling system hoses (as necessary).
5) On Golf, GTI and Jetta models, remove grille from radiator
support. Disconnect electrical connectors at radiator support. Remove
radiator-to-support bolts. Remove radiator support using care not
damage headlights. Remove radiator, fan and shroud assembly.
6) On all models, remove axle shafts from transaxle. See FWD
AXLE SHAFTS article in the DRIVE AXLES section. Mark and disconnect
shift linkage and speedometer cable. Mark and remove electrical
connectors and vacuum hoses (as necessary). Disconnect throttle,
cruise and kickdown cables (if equipped). Leave fuel lines connected
and remove cold start injector and warm-up regulator.
7) Remove fuel injectors and install protective caps and
plugs. Remove rear engine mount. Remove complete transaxle mount. On
Cabriolet models, remove right front tire assembly. Remove right and
left engine mount through bolts.
8) On all models, install engine sling on engine lift hooks.
Carefully raise engine and transaxle out of vehicle. Separate
transaxle from engine (if necessary).
INSTALLATION
1) To install, reverse removal procedure. Engine alignment
adjustment is necessary whenever engine is removed or mounts are
loosened. To adjust, loosen through bolt on engine mount "A". Loosen
transmission transaxle mount "B" bolts. Loosen front engine mount and
bracket. See Fig. 2.
2) Lightly rock engine and transaxle to allow position to

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
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 09:40PM
shift as necessary. Evenly tighten mount bolts in reverse order of
loosening. Fill fluids to proper level. Adjust clutch pedal (if
equipped). Tighten all bolts and nuts to specifications.
ENGINE R & I (FOX)
REMOVAL (FOX)
1) Disconnect negative battery cable. Open heater valve,
coolant expansion tank and drain radiator through lower radiator hose.
Mark and disconnect all heater hoses. Disconnect electric cooling fan
and thermo switch. Remove lower and side radiator mounting bolts.
Remove fan, shroud and radiator. Remove M/T clutch cable (if
equipped).
2) Mark and disconnect electrical wiring and vacuum hoses (as
necessary). Disconnect throttle, cruise and kickdown linkage (if
equipped). Remove fuel injectors and install protective caps and
plugs. Leave fuel lines attached and remove cold start valve. Remove
charcoal canister and set aside.
3) Remove 3 upper engine-to-transaxle bolts. Remove intake
air duct. Remove left and right engine mount nuts. Disconnect and
remove starter assembly. Remove 2 lower engine-to-transaxle bolts.
Remove transaxle inspection cover plate. Disconnect exhaust inlet pipe
support and separate inlet pipe from exhaust manifold.
4) Support transaxle. Attach engine sling to engine lifting
hooks. Raise engine/transaxle until engine clears engine mounts.
Ensure transaxle is supported. Remove remaining engine-to-transaxle
bolts. Lift and separate engine from vehicle without transaxle.
INSTALLATION
Lubricate transaxle main shaft splines and contact area
between clutch release bearing and clutch pressure plate with MoS2
grease. DO NOT lubricate guide sleeve for clutch release bearing. To
complete installation, reverse removal procedure. DO NOT reuse self-
locking nuts. Ensure engine mounts are installed to original location.
Tighten engine mounts and subframe bolts with engine running at idle.

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
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 09:40PMFig. 2: Engine/Transaxle Alignment
Courtesy of Volkswagen United States, Inc.
INTAKE MANIFOLD R & I
Removal and installation procedure is not available from
manufacturer. See TORQUE SPECIFICATIONS table at end of this article.
EXHAUST MANIFOLD R & I
Removal and installation procedure is not available from
manufacturer. See TORQUE SPECIFICATIONS table at end of this article.
CYLINDER HEAD R & I
REMOVAL
No removal procedure available from manufacturer. Cylinder
head may be removed with engine in vehicle. Match mark all components
for installation reference. Timing belt must be removed. See TIMING
BELT R & I in this article. See Fig. 3 or 4. Remove cylinder head
bolts in reverse sequence of installation. See Fig. 5. Replace
cylinder head bolts after loosening or removing.

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
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 09:40PMFig. 4: Exploded View of 8-Valve Cylinder Head
Courtesy of Volkswagen United States, Inc.
INSPECTION
Thoroughly clean all gasket mating surfaces. Check cylinder
head for warpage. The 8-valve cylinder head can be machined and 16-
valve cylinder head cannot be machined. Check camshaft(s). See
INSPECTION under CAMSHAFT R & I in this article. See ENGINE
SPECIFICATIONS at end of this article.
NOTE: DO NOT reuse antifreeze after replacing cylinder block,
cylinder head, head gasket, radiator and/or heater core.

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
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 09:40PM
2) Align crankshaft sprocket mark with mark on lower timing
belt cover. See Fig. 10. Install timing belt around camshaft sprocket.
Rotate tensioner clockwise until Timing Belt Tension Scale (VW 210)
reads 13-14. Rotate crankshaft 2 revolutions and check timing mark
alignment. To complete installation, reverse removal procedure.
CAMSHAFT OIL SEAL R & I
REMOVAL
1) Remove upper timing belt cover. Place crankshaft at TDC
with No. one cylinder on compression stroke. Remove timing belt from
camshaft sprocket. Remove camshaft sprocket. Remove Woodruff key.
Install camshaft sprocket bolt and washer until washer is tight
against camshaft.
2) Rotate inner part of Oil Seal Extractor (2085) outward 2
turns and tighten set screw. See Fig. 11. Lubricate threaded area of
extractor and push in as far as possible. Loosen set screw and turn
inner part of extractor until oil seal is removed.
INSTALLATION
Coat new seal seat and lips lightly with engine oil. Using
Installer (10-203), install seal until flush. On 16-valve engines, use
Special Hex Head Bolt (10-203/1). To complete installation, reverse
removal procedure.Fig. 11: Removing Camshaft Oil Seal
Courtesy of Volkswagen United States, Inc.
CAMSHAFT R & I (8-VALVE)
CAUTION: Mark components to ensure installation to original location
and position. Components are not interchangeable.
REMOVAL (8-VALVE)
1) Remove upper timing belt cover. See Fig. 6. Remove valve
cover. Place crankshaft at TDC with No. one cylinder on compression

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
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 09:40PM
stroke. Remove timing belt from camshaft sprocket. Remove camshaft
sprocket. Remove Woodruff key. Check camshaft end play with cam
followers removed and bearing cap Nos. 1 and 5 installed. See CAMSHAFT
table at end of this article.
2) Remove bearing cap Nos. 1, 3 and 5 evenly a little at a
time. Repeat for remaining caps. Lift camshaft out of cylinder head.
See INSPECTION below.
INSPECTION
1) Check camshaft bearing oil clearance. See ENGINE
SPECIFICATIONS at end of this article. If oil clearance is greater
than specifications, install new camshaft and recheck clearance.
2) If clearance is still greater than specifications,
replace cylinder head. If replacing camshaft(s), ensure identification
number between lobes of cylinder No. one, are the same.
INSTALLATION (8-VALVE)
1) On engines with oil spray jets, position spray at right
angle to camshaft. Place camshaft in cylinder head with both high
points of lobes, for No. one cylinder facing upward. Install bearing
cap Nos. 1, 3 and 5.
2) Tighten evenly a little at a time. Repeat procedure for
remaining bearing caps. To complete installation, reverse removal
procedure. Ensure timing marks are properly aligned. Allow lifters to
bleed down for 30 minutes before starting engine.
CAMSHAFT R & I (16-VALVE)
REMOVAL (16-VALVE)
1) Remove upper timing belt cover. See Fig. 6. Remove valve
cover. Place crankshaft at TDC with No. one cylinder on compression
stroke. Remove timing belt from camshaft sprocket. Remove camshaft
sprocket. Remove Woodruff key. Check camshaft end play with cam
followers removed and bearing cap Nos. 1 and 4 (exhaust cam) or 5 and
8 (intake cam) installed. See CAMSHAFT SPECIFICATIONS table at the end
of this article.Fig. 12: 16-Valve Camshaft Bearing Caps
Courtesy of Volkswagen United States, Inc.

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
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 09:40PM
2) Remove intake camshaft bearing cap Nos. 5, 7 and rear
evenly a little at a time. See Fig. 12. Loosen remaining intake
camshaft bearing caps evenly a little at a time. Remove exhaust
camshaft bearing cap Nos. 1, 3, front and rear evenly a little at a
time. Loosen remaining exhaust camshaft bearing caps evenly a little
at a time. Remove loosened caps. Lift camshafts out of cylinder head
together.
INSPECTION
1) Check camshaft bearing oil clearance. See ENGINE
SPECIFICATIONS at end of this article. If oil clearance is greater
than specifications, install new camshaft and recheck clearance.
2) If clearance is still greater than specifications, replace
cylinder head. If replacing camshaft(s), ensure identification number
between lobes of cylinder No. one, are the same.
INSTALLATION (16-VALVE)
1) On engines with oil spray jets, position spray at right
angle to camshaft. Place chain on both camshaft gears. Align marks on
gears and place both camshafts in cylinder head as shown. See Fig. 13.
2) Install intake camshaft bearing cap Nos. 6 and 8 and
tighten evenly a little at a time. See Fig. 12. Repeat procedure for
remaining intake camshaft bearing caps. Install exhaust bearing cap
Nos. 2 and 4 and tighten evenly a little at a time. Repeat procedure
for remaining exhaust bearing caps. To complete installation, reverse
removal procedure. Allow 30 minutes before starting engine for lifters
to bleed down.Fig. 13: 16-Valve Camshaft Gear Position
Courtesy of Volkswagen United States, Inc.
VALVE ARRANGEMENT
8-Valve Engines
E-I-E-I-I-E-I-E (Front-to-Rear).
16-Valve Engines