sensor VOLKSWAGEN CORRADO 1990 Workshop Manual

ANTI-LOCK BRAKE SYSTEM
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 09:42PM
style and type. Failure to follow this precaution may cause
inaccurate wheel speed readings.
* DO NOT contaminate speed sensor components with grease. Only
use recommended anti-corrosion coating.
* When speed sensor components have been removed, ALWAYS check
sensor-to-ring gap when applicable. These specifications can
be found in WHEEL SPEED SENSOR under ADJUSTMENTS.
* ONLY use recommended brake fluids. DO NOT use silicone brake
fluids in an ABS equipped vehicle.
* When installing transmitting devices (CB's, telephones, ect.)
on ABS equipped vehicles, DO NOT locate antenna near the ABS
control unit or any control unit.
* Disconnect all on-board computers when using electric welding
equipment.
* DO NOT expose the ABS control unit to prolonged periods of
high heat (185øF/85øC for 2 hours is generally considered a
maximum limit).
CAUTION: The ABS system is under extremely high pressure.
Depressurize the brake system before loosening or removing
any hydraulic component.
DEPRESSURIZING BRAKE SYSTEM
Turn ignition off. Depress and release brake pedal 25-35
times, or until there is a noticeable increase in the effort to
depress the brake pedal. Do not turn ignition on until all hydraulic
lines and components are fully tighten.
BLEEDING BRAKE SYSTEM
FRONT BRAKES
Depressurize brake system. See DEPRESSURIZING BRAKE SYSTEM.
Connect a container with hose to left front bleeder screw. Have
assistant depress and release brake pedal a few times. Holding brake
pedal down, open bleeder screw and allow fluid to enter container.
Close bleeder screw and then release brake pedal. Continue this method
until no air is present in fluid. Check master cylinder fluid level to
make sure it does not go below minimum level mark. Use same procedure
for right front brake.
REAR BRAKES
CAUTION: When bleeding rear brakes, accumulator pressure (about 3100
psi) is used to assist in procedure. Use eye protection
when performing this procedure. DO NOT allow pump to run
longer than 2 minutes. See ANTI-LOCK BRAKE SAFETY
PRECAUTIONS in this article.
Attach hose and container to right rear bleeder screw.
Position actuator lever on load-sensing pressure regulator toward rear

ANTI-LOCK BRAKE SYSTEM
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 09:42PM
Turn ignition on. Apply brakes. Check for 12 volts between
terminals No. 12 and 1. If 12 volts are present, brakelight switch is
okay. If 12 volts are not present, check fuse, brakelight switch and
Black/Red wire from brakelight switch to ECU.
Hydraulic Modulator/Pump Relay Voltage Test
1) Turn ignition off. Unplug hydraulic modulator/pump
connector. Depress brake pedal 25 times. Turn ignition on. Using a
voltmeter, measure voltage between ECU connector terminals No. 1 and
32. See Fig. 2. If voltage is 10 volts or more, go to RIGHT REAR WHEEL
SPEED SENSOR VOLTAGE TEST under SYSTEM TESTING.
2) If voltage is less than 10 volts, check hydraulic
modulator/pump fuse. If fuse is okay, check wiring between ECU
connector terminal No. 32 and hydraulic modulator/pump connector
terminal No. 1 (large gauge Red/Black wire). See Figs. 2 and 4-9. If
wiring is not okay, repair wiring, and retest. If wiring is okay,
replace relay, and retest.
Right Rear Wheel Speed Sensor Voltage Test
Connect an AC voltmeter between ECU connector terminals No. 4
and 22. See Fig. 2. Rotate right rear wheel at one revolution per
second. Measure voltage with wheel rotating. If voltage is 0.075 volt
or more, go to next test. If voltage is less than 0.075 volt, check
wheel speed sensor and/or toothed ring for damage, wear and proper
installation. If damage or wear is found, replace faulty component and
retest. If not properly installed, reposition and retest. If
components are okay, replace wheel speed sensor and retest.
Left Rear Wheel Speed Sensor Voltage Test
Connect an AC voltmeter between ECU connector terminals No. 6
and 24. See Fig. 2. Rotate left rear wheel at one revolution per
second. Measure voltage with wheel rotating. If voltage is 0.075 volt
or more, go to next test. If voltage is less than 0.075 volt, check
wheel speed sensor and/or toothed ring for damage, wear and proper
installation. If damage or wear is found, replace faulty component and
retest. If not properly installed, reposition and retest. If
components are okay, replace wheel speed sensor and retest.
Right Front Wheel Speed Sensor Voltage Test
Connect an AC voltmeter between ECU connector terminals No. 7
and 25. See Fig. 2. Rotate right front wheel at one revolution per
second. Measure voltage with wheel rotating. If voltage is 0.075 volt
or more, go to next test. If voltage is less than 0.075 volt, check
wheel speed sensor and/or toothed ring for damage, wear and improper
installation. If damage or wear is found, replace faulty component,
and retest. If component is improperly installed, reposition
component, and retest. If components are okay, replace wheel speed
sensor, and retest.
Left Front Wheel Speed Sensor Voltage Test
Connect an AC voltmeter between ECU connector terminals No. 5
and 23. See Fig. 2. Rotate left front wheel at one revolution per

ANTI-LOCK BRAKE SYSTEM
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 09:42PM
second. Measure voltage with wheel rotating. If voltage is 0.075 volt
or more, go to next test. If voltage is less than 0.075 volt, check
wheel speed sensor and/or toothed ring for damage, wear and proper
installation. If damage or wear is found, replace faulty component and
retest. If not properly installed, reposition and retest. If
components are okay, replace wheel speed sensor and retest.
ECU Relay Continuity Test
Turn ignition off. Using an ohmmeter, check for continuity
between ECU connector terminals No. 1 and 3, and between terminals No.
1 and 20. See Fig. 2. If there is continuity at both test points, go
to next test. If there is no continuity at either or both test points,
check wiring. If wiring is faulty, repair and retest. If wiring is
okay, replace relay and retest.
Solenoid Valves Ground Circuit Continuity Test
1) Turn ignition off. Remove jumper wire from previous test.
Using an ohmmeter, check for continuity between ECU connector
terminals No. 1 and 11. See Fig. 2. If there is continuity, go to next
step.
2) If continuity does not exist, check for continuity between
ECU connector terminal No. 1 and valve block housing and between
hydraulic modulator and valve block housing. If continuity does not
exist between ECU connector terminal No. 1 and valve block housing,
repair wiring, and retest. If continuity does not exist between
housings, repair as necessary.
3) Reconnect jumper wire between ECU connector terminals No.
1 and 11. Check for continuity between ECU connector terminal No. 11
and valve block connector terminal No. 1 (Brown wire). See Figs. 2, 4-
9. If there is no continuity, repair wiring and retest.
Hydraulic Modulator/Pump Relay Ground Circuit Test
Turn ignition off. Reconnect pressure switch connector.
Depress brake pedal 20 times. Using an ohmmeter, check for continuity
between ECU connector terminals No. 1 and 14. If continuity exists, go
to next test. If continuity does not exist, check for continuity
between pressure switch terminals No. 1 (Brown wire) and 4 (Red/Yellow
or White wire). See Figs. 1 and 4-9. If continuity does not exist,
replace pressure switch, and retest. If continuity exists, check
wiring between ECU terminal No. 14 and pressure switch terminal No. 4.
Repair wiring, and retest.
Low Pressure Warning Switch Test
Turn ignition off. Ensure brake fluid level is okay and fluid
level sensor switch float is in correct position (switch is in closed
position). Ensure accumulator is fully charged and pump is not
operating. Using an ohmmeter, check for continuity between ECU
connector terminals No. 9 and 10. See Fig. 2. If there is continuity,
switch is okay. If contiuity does not exist, check wiring. If wiring
is okay, replace switch, and retest.
Right Rear Wheel Speed Sensor Resistance Test

ANTI-LOCK BRAKE SYSTEM
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 09:42PM
Turn ignition off. Using an ohmmeter, measure resistance
between ECU connector terminals No. 4 and 22. See Fig. 2. If
resistance is 800-1400 ohms, go to next test. If resistance is not as
specified, check resistance at right rear wheel speed sensor. If
resistance is correct, repair wiring and retest. If resistance is not
correct, replace wheel speed sensor and retest.
Left Rear Wheel Speed Sensor Resistance Test
Using an ohmmeter, measure resistance between ECU connector
terminals No. 6 and 24. See Fig. 2. If resistance is 800-1400 ohms, go
to next test. If resistance is not as specified, check resistance at
left rear wheel speed sensor. If resistance is correct, repair wiring
and retest. If resistance is not correct, replace wheel speed sensor,
and retest.
Right Front Wheel Speed Sensor Resistance Test
Using an ohmmeter, measure resistance between ECU connector
terminals No. 7 and 25. See Fig. 2. If resistance is 800-1400 ohms, go
to next test. If resistance is not as specified, check resistance at
right front wheel speed sensor. If resistance is correct, repair
wiring and retest. If resistance is not correct, replace wheel speed
sensor and retest.
Left Front Wheel Speed Sensor Resistance Test
Using an ohmmeter, measure resistance between ECU connector
terminals No. 5 and 23. See Fig. 2. If resistance is 800-1400 ohms, go
to next test. If resistance is not as specified, check resistance at
left front wheel speed sensor. If resistance is correct, repair
wiring, and retest. If resistance is not correct, replace wheel speed
sensor, and retest.
Right Rear Wheel Speed Sensor Shielding Resistance Test
Using an ohmmeter, measure resistance between ECU connector
terminals No. 4 and 1. See Fig. 2. If resistance is 20,000 ohms or
more, go to next test. If resistance is less than 20,000 ohms, check
shielding wire for damage. Replace harness if damage is found and
retest.
Left Rear Wheel Speed Sensor Shielding Resistance Test
Using an ohmmeter, measure resistance between ECU connector
terminals No. 6 and 1. See Fig. 2. If resistance is 20,000 ohms or
more, go to next test. If resistance is less than 20,000 ohms, check
shielding wire for damage. Replace harness if damage is found and
retest.
Right Front Wheel Speed Sensor Shielding Resistance Test
Using an ohmmeter, measure resistance between ECU connector
terminals No. 7 and 1. See Fig. 2. If resistance is 20,000 ohms or
more, go to next test. If resistance is less than 20,000 ohms, check
shielding wire for damage. Replace harness if damaged, and retest.
Left Front Wheel Speed Sensor Shielding Resistance Test

ANTI-LOCK BRAKE SYSTEM
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 09:42PM
REMOVAL & INSTALLATION
HYDRAULIC MODULATOR/PUMP
Removal & Installation
1) Depressurize brake system. See DEPRESSURIZING BRAKE
SYSTEM. Disconnect negative battery cable. Unplug all electrical
connectors from hydraulic modulator/pump. Identify and disconnect all
hydraulic lines from hydraulic modulator/pump. Plug all line openings.
2) From inside passenger compartment, remove push rod clevis
pin. Remove hydraulic modulator/pump retaining nuts. Remove hydraulic
modulator/pump. To install, reverse removal procedure. Tighten all
fittings to specification. See TORQUE SPECIFICATIONS TABLE at end of
article. Bleed brake system. See BLEEDING BRAKE SYSTEM.
WHEEL SPEED SENSORS
NOTE: To protect magnetic part of sensor, always leave new wheel
speed sensor in special packaging until ready for
installation.
Removal & Installation
Remove bolt retaining wheel speed sensor. Unplug connector.
Remove wheel speed sensor. To install, apply Lubricant (G-000-650) to
sensor. Install sensor, and tighten retaining bolt to 84 INCH lbs. (10
N.m).
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplications Ft. Lbs. (N.m)
Brake Lines-To-Hydraulic Modulator/Pump ............... 11 (15)
Hydraulic Modulator/Pump Retaining Nuts ............... 18 (25)
INCH Lbs. (N.m)
Wheel Sensor Retaining Bolt .......................... 84 (9.5)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ WIRING DIAGRAMS

B - EMISSION APPLICATION
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:43PM
ARTICLE BEGINNING
1990 ENGINE EMISSIONS
Emission Control Applications
Cabriolet, Corrado, Fox, Golf, Jetta, Passat, Vanagon
EMISSION CONTROL DEVICE APPLICATIONS
EMISSION CONTROL DEVICE APPLICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Devices
Cabriolet 1.8L (CIS-E) PCV, EVAP, TWC, SPK, O2, CEC,
EVAP-PV, EVAP-VC, SPK-CC, VA
Corrado 1.8L (PFI) PCV, EVAP, TWC, O2, CEC,
PCV-HCB, EVAP-PV, EVAP-VC, SPK-CC
Fox 1.8L (CIS-E) PCV, EVAP, TWC, EGR (Calif.), O2,
CEC, EVAP-VC, EVAP-VS, EGR-VA (Calif.),
EGR-TVV (Calif.), SPK-CC, VA
Golf & Jetta
1.8L (CIS-E) PCV, EVAP, TWC, SPK, O2, CEC,
CE, EVAP-VC, EVAP-PV, SPK-CC, VA
2.0L (CIS-E) PCV, EVAP, TWC, EGR, SPK, O2, CEC,
CE, EVAP-VC, EGR-TVV, SPK-CC,
Passat 2.0L CIS-E PCV, EVAP, TWC, EGR (Calif.),
SPK, O2, CEC, CE, EVAP-VC,
EVAP-SV, EGR-TVV, SPK-CC,
Vanagon PFI PCV, EVAP, TWC, EGR, SPK, O2, CEC, EMR,
CE, EVAP-VC, EVAP-PV, SPK-CC, VA, VR
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ ABBREVIATION DEFINITIONS
CEC - Computerized Engine Control
CE - Check Engine Light
CIS-E - Continuous Injection System-Electronic
EGR - Exhaust Gas Recirculation
EGR-VA - EGR-Vacuum Amplifier
EGR-TS - EGR Temperature Sensor
EGR-TVV - EGR Thermal Vacuum Valve
EVAP - Fuel Evaporation System
EVAP-CS - EVAP Control Solenoid

B - EMISSION APPLICATION
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 09:43PM
EVAP-PVB - EVAP Purge Valve
EVAP-SV - EVAP Solenoid Valve
EVAP-VC - EVAP Vacuum Canister
EVAP-VS - EVAP Vacuum Sensor
O2 - Oxygen Sensor
OC - Oxidation Catalyst
PAS - Pulse Air Injection System
PCV - Positive Crankcase Ventilation
PCV-HCB - PCV Heated Crankcase Breather
PFI - Programmed Fuel Injection
SPK - Spark Timing Control
SPK-CC - Spark Computer Controlled
TAC - Thermostatic Air Cleaner
TWC - Three-Way Catalyst
VA - Vacuum Amplifier
VR - Vacuum Retard
VS - Vacuum Sensor
END OF ARTICLE

C - SPECIFICATIONS
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 09:43PMFig. 2: 2.1L Firing Order & Distributor Rotation
Courtesy of Volkswagen United States, Inc.
IGNITION TIMING
1.8L & 2.0L
Timing mark location is on flywheel. Timing pointer is on
timing hole on transaxle bellhousing.
2.1L
Timing mark on crankshaft belt pulley and notch on "V" belt
pulley must align with separating line of crankcase.
NOTE: Always reference under-hood label for latest specifications.
IGNITION TIMING TABLE (1)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Checking Adjusting
1.8L ................ 4-8 @ 870-930 ........... 5-7 @ 870-930
2.0L ................ 4-8 @ 770-830 ........... 5-7 @ 770-830
2.1L ................ 4-8 @ 800-900 ........... 5-7 @ 800-900
(1) - Degrees BTDC @ RPM.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄNOTE: Off idle timing is computer controlled on models with knock
sensor. For adjustment procedures, see D - ADJUSTMENTS
article.
DISTRIBUTOR ADVANCE SPECIFICATIONS TABLE
DISTRIBUTOR ADVANCE TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Degrees
Total Advance RPM
Cabriolet & Fox .............. 22-26 ................... 4500
Golf GL & Jetta .............. 23-27 ................... 6000

D - ADJUSTMENTS
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:43PM
ARTICLE BEGINNING
1990 ENGINE PERFORMANCE
On-Vehicle Adjustments
Volkswagen; Cabriolet, Corrado, Fox, Golf GL/GTI,
Jetta, Vanagon
ENGINE COMPRESSION
Check engine compression with engine at normal operating
temperature at specified cranking speed, all spark plugs removed and
throttle wide open.
ENGINE COMPRESSION TESTÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄModel Standard Minimum
psi (kg/cm
ý) psi (kg/cmý)
Cabriolet ............. 131-174 (9.0-12.0) ............. 109 (7.5)
Corrado ............... 116-174 (8.0-12.0) .............. 87 (6.0)
Fox ................... 131-174 (9.0-12.0) ............. 102 (7.0)
Golf GL/GTI 1.8L ...... 131-174 (9.0-12.0) ............. 102 (7.0)
Jetta ................. 131-174 (9.0-12.0) ............. 102 (7.0)
Jetta GLi 2.0L ........ 145-190 (10.0-13.0) ............ 109 (7.5)
Vanagon ............... 87-131 (6.1-9.2) ................ 87 (6.0)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ VALVE CLEARANCE
NOTE: All models use hydraulic lifters. No adjustments are
required.
IGNITION TIMING
NOTE: Basic timing readings are only valid when engine idle speed
and idle mixture are within specifications. For best
results, the manufacturer recommends ignition timing, idle
CO and idle speed be checked and adjusted in that order.
NOTE: Off idle timing is computer controlled on models with knock
sensor(s). Only idle ignition timing can be set.
ALL MODELS EXCEPT VANAGON
1) Warm engine to normal operating temperature (cooling fan
should cycle at least once). Remove the 27 mm plastic plug from timing
check hole on transaxle bellhousing.
2) With ignition off, connect a tachometer and timing light
to vehicle. Start engine, raise speed above 2100 RPM a few times, and
allow engine to idle normally. With distributor vacuum hoses

D - ADJUSTMENTS
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 09:43PM
NOTE: Mixture adjustment is NOT a part of normal tune-up procedure
and should not be performed unless mixture control unit is
replaced or vehicle fails emissions testing.
NOTE: Ensure system pressure is correct before attempting idle
speed or mixture adjustment.
IDLE SPEED & MIXTURE ADJUSTMENT
FOX (CIS-E) & JETTA GLI 2.0L (CIS-MOTRONIC)
1) Ignition timing and idle speed must be checked before CO
is adjusted. See CHECKING & ADJUSTING under IGNITION TIMING. With
ignition timing properly adjusted, check and adjust idle speed,
differential pressure regulator current and idle mixture. Repeat the
adjustments until all occur at the same time.
2) Warm engine to normal operating temperature. Radiator fan
must come on at least once and engine oil temperature must be at least
176øF (80øC). Turn off all electrical equipment, including A/C and
radiator fan. Disconnect all fuel pressure test equipment (if
installed). If injection lines have been removed or replaced, run
engine several times to 3000 RPM for about 2 minutes.
3) Ensure idle switch is properly adjusted. Check that
auxiliary air regulator valve is fully closed. Pinch shut the hose
leading from the idle speed boost valve(s). Remove temperature sensor
harness connector from the temperature sensor. Pull crankcase breather
hoses off valve cover and air filter, vent to atmosphere.
4) Remove suction hose from carbon canister. Disconnect "T"
fitting from carbon canister at air intake boot. On Fox models only,
remove connector from coolant temperature sensor and install 15,000-
ohm resistor (VW 1490) on temperature sensor harness. See Fig. 1.Fig. 1: Fox Coolant Temperature Sensor Location & 15,000-Ohm Test
Resistor
Courtesy of Volkswagen United States, Inc.
5) Turn "T" fitting 90 degrees and insert blank side with .