VOLKSWAGEN CORRADO 1990 Repair Manual

I - SYSTEM/COMPONENT TESTS
Article Text (p. 14)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:46PM
terminals. Disconnect Hall Effect sender wire harness connector from
distributor. Turn ignition on.
2) While observing DVOM reading, attach center terminal of
connector to ground for 3 seconds. Voltage reading should briefly
increase to 4.5 volts. If voltage reading did not increase, check
wiring for short or open circuit. If wiring is okay, replace ignition
control unit.
EMISSION SYSTEMS & SUB-SYSTEMS
EXHAUST GAS RECIRCULATION (EGR)
1) With engine idling, apply about 12 in. Hg to EGR valve
with a hand-held vacuum pump. Engine should run rough or stall. If
idle does not change, remove EGR valve and inspect for restricted port
passage. Clean as required.
2) If port is clean, apply about 12 in. Hg to EGR valve with
vacuum pump. If valve does not move, replace EGR valve. If valve
moves, go to next step.
3) Install EGR valve and new gasket. Connect vacuum gauge to
EGR vacuum line with a "T" fitting. Start engine and increase engine
speed to about 3000 RPM. Vacuum gauge should indicate vacuum. If okay,
test is complete. If not okay, vacuum source is plugged. Repair as
necessary and repeat test.
FUEL EVAPORATION
EVAP CANISTER BY-PASS VALVE (ALL MODELS EXCEPT VANAGON)
1) Remove both vent hoses and vacuum hose from canister by-
pass valve. Apply very low air pressure to vent hoses individually.
There should be no airflow. If air passes through, replace by-pass
valve.
2) Attach vacuum pump to vacuum hose and apply 5-10 in. Hg.
Apply low air pressure to vent hoses individually. Valve should be
open and air should flow. If air does not flow, replace by-pass valve.
EVAP CANISTER BY-PASS VALVE (VANAGON)
1) Start and warm engine to normal operating temperature.
Disconnect White nylon hose from rubber boot at rear of intake
manifold. Attach vacuum pump and apply 5-10 in. Hg. If vacuum holds,
control valve is okay.
2) If vacuum does not hold, disconnect Purple vacuum hose
from throttle body. Attach vacuum gauge. If less than one in. Hg is
present, replace control valve. If more than one in. Hg is present,
adjust throttle valve stop screw and repeat test.

I - SYSTEM/COMPONENT TESTS
Article Text (p. 15)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:46PMFig. 12: Identifying Typical Fuel Evaporation System Components
Courtesy of Volkswagen United States, Inc.Fig. 13: Identifying Knock Sensor Control Unit Terminal
Courtesy of Volkswagen United States, Inc.
MISCELLANEOUS CONTROLS
A/C CLUTCH
See IDLE STABILIZATION SYSTEM (VANAGON) in this article.
END OF ARTICLE

INSTRUMENT PANEL
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:46PM
ARTICLE BEGINNING
1989-90 ACCESSORIES & EQUIPMENT
Volkswagen Instrument Panels
Cabriolet, Fox, Golt, GTI, Jetta, Jetta GLI, Vanagon
DESCRIPTION & OPERATION
Instrument cluster for most models includes speedometer, fuel
gauge and temperature gauge. Optional instruments include clock,
tachometer, voltmeter and oil temperature gauge.
Printed circuit provides voltage to gauges. A voltage
regulator attached to the printed circuit controls voltage to fuel and
temperature gauges. Light Emitting Diodes (LEDs) are used for most
warning lights. To replace diodes, pull from printed circuit sockets.
NOTE: Volkswagen Tester (1301) is required for resistance tests.
Tester settings are numerical. Settings do not indicate
resistance in ohms. Manufacturer does not supply resistance
value in ohms.
TESTING
FUEL & TEMPERATURE GAUGE
1) Disconnect wire from fuel tank or temperature sending
unit. Connect VW tester between wire and ground. Turn ignition on and
allow 2 minutes for gauge reading to stabilize. Use FUEL GAUGE TESTING
or TEMPERATURE GAUGE TESTING table to compare gauge reading. Gauge
should be within one pointer width of specification.
2) If gauge needle does not move, check continuity between
sender wire and gauge. If needle moves, but does not match
specifications, replace gauge. If gauge works correctly with tester,
but not sending unit, replace sending unit.
FUEL GAUGE TESTINGÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Dial Setting Indicator
Cabriolet & Fox .......... 55 ................ Full
560 ................Empty
Golf, GTI, Jetta
& Jetta GLI .............. 52 ................ Full
550 ................Empty
Vanagon .................. 50 ................ Full
320 ................Empty
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄTEMPERATURE GAUGE TESTING
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

INSTRUMENT PANEL
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 09:46PM
Application Dial Setting Indicator
Cabriolet ................ 500 ............... Cold
62 ...................Hot
Golf, GTI, Jetta,
Jetta GLI & Vanagon .... 510 ............... Cold
50 ...................HotÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ VOLTAGE REGULATOR
1) If only one gauge is inoperative, regulator is not
defective. If both fuel and temperature gauges are inoperative,
voltage regulator may be faulty or have a bad ground connection.
2) Partially remove instrument cluster. Position cluster so
regulator can be reached with voltmeter probes. Leave chassis harness
connected. Ensure ground connection at regulator is tight.
3) Turn ignition on. Connect voltmeter negative lead (-) to
terminal No. 2 of regulator. Connect positive lead (+) to terminal No.
1. See Fig. 1. Meter reading should be 10 volts with an allowable
tolerance of .5 volt. If voltage reading exceeds specification,
replace voltage regulator.Fig. 1: Testing Voltage Regulator
Courtesy of Volkswagen United States, Inc.
REMOVAL & INSTALLATION
INSTRUMENT CLUSTER - CABRIOLET

INSTRUMENT PANEL
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 09:46PM
Removal & Installation
Disconnect negative battery cable. Remove steering wheel.
Pull tilt shelf downward. Remove 3 shelf retaining screws and remove
shelf. Remove 3 instrument panel lower retaining screws and and pry
off 3 clips. Remove 2 instrument trim retaining screws and remove
instrument panel trim. Remove center instrument cluster screw and tip
instrument panel cluster forward. Remove speedometer cable and wiring
connector from back of cluster. Remove instrument panel cluster. To
install, reverse removal procedure.
INSTRUMENT CLUSTER - FOX
Removal & Installation
Disconnect negative battery cable. Remove steering wheel.
Carefully remove covers from vacant switch position. Depress switch
spring retainer and remove switches from instrument panel. Disconnect
wire connectors from switches. Remove 4 instrument cluster trim
retaining screws. Remove instrument cluster trim panel. Remove 2
instrument cluster retaining screws. Remove speedometer cable.
Disconnect cluster wire connector and remove instrument cluster. To
install, reverse removal procedure.
INSTRUMENT CLUSTER - GOLF, GTI, JETTA & JETTA GLI
Removal & Installation
Remove temperature control knobs, levers and trim plate.
Remove radio or convenience tray. Remove switches from instrument
panel trim plate. Remove instrument panel trim plate. Remove 2
mounting screws and pull instrument cluster outward. Remove
speedometer cable, vacuum hoses, and electrical connections. To
install, reverse removal procedures.
INSTRUMENT CLUSTER - VANAGON
Removal & Installation
Disconnect negative battery cable. Reach behind cluster hood
and pull back of hood upward. Pull hazard switch forward. Pull brake
warning light housing toward front of vehicle. Remove 4 mounting
screws and remove cluster. To install, reverse removal procedure.
COMBINATION SWITCH
Removal
Remove steering wheel. Remove column cover. Disconnect wiring
and remove 3 switch screws. Remove switches.
Installation
Install switches on column. Place steering wheel on column
and ensure clearance between wheel and turn signal switch is 1/16-
1/8". Move spacer sleeve up or down to adjust clearance. Tighten
steering wheel nut to 36 ft. lbs. (50 N.m) and replace pad.

INSTRUMENT PANEL
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 09:46PM
WIRING DIAGRAMS
NOTE: See appropriate chassis wiring diagram in the WIRING DIAGRAMS
section.
END OF ARTICLE

INTERFERENCE VERIFICATION CHECK FOR OHC ENGINE
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:46PM
ARTICLE BEGINNING
Maintenance & Service Information
1974-96 Volkswagen - Timing Belt Information
Cabrio, Cabriolet, Corrado, Dasher, Eurovan (Canadian), Fox,
Golf, Golf (Canadian), GTI, GTI (Canadian), Jetta, Jetta GLI,
Passat, Passat (Canadian), Pickup, Quantum, Rabbit, Scirocco,
Scirocco (Canadian), Transporter (Canadian), Vanagon
TIMING BELT INTERFERENCE VERIFICATION INFORMATION
TIMING BELT INTERFERENCE CAUTION
NOTE: CAMSHAFT DRIVE BELTS OR TIMING BELTS - The condition of
camshaft drive belts should always be checked on vehicles
which have more than 50,000 miles. Although some
manufacturers do not recommend replacement at a specified
mileage, others require it at 60,000-100,000 miles. A
camshaft drive belt failure may cause extensive damage to
internal engine components on most engines, although some
designs do not allow piston-to-valve contact. These designs
are often called "Free Wheeling". Many manufacturers changed
their maintenance and warranty schedules in the mid-1980's to
reflect timing belt inspection and/or replacement at
50,000-60,000 miles. Most service interval schedules shown in
this section reflect these changes. Belts or components
should be inspected and replaced if any of the following
conditions exist:
* Crack Or Tears In Belt Surface
* Missing, Damaged, Cracked Or Rounded Teeth
* Oil Contamination
* Damaged Or Faulty Tensioners
* Incorrect Tension Adjustment
TIMING BELT INTERFERENCE CHECK MENU
TIMING BELT INTERFERENCE VERIF. TABLE - PASSENGER CARS (1)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Replacement Interval
Application Engine (Miles)
Cabrio
1995-96 .......... 2.0L 4-Cyl. ............ (3) 60,000
Cabriolet
1985-89 ....... 1.8L 4-Cyl. (DOHC) ........ (3) 60,000
1.8L 4-Cyl. (SOHC) ........ (3) 60,000
1990-93 .......... 1.8L 4-Cyl. ............ (3) 60,000
Corrado
1990-92 .......... 1.8L 4-Cyl. ............ (3) 60,000
Dasher

INTERFERENCE VERIFICATION CHECK FOR OHC ENGINE
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 09:46PM
1976-80 ..... (2) 1.5L 4-Cyl. Diesel ...... (3) 60,000
1974-80 .......... 1.6L 4-Cyl. ............ (3) 60,000
1981-80 ......... (2) 1.6L 4-Cyl.
Diesel & Turbo Diesel ...... (3) 60,000
Fox
1987-93 .......... 1.8L 4-Cyl. ............ (3) 60,000
Golf
1985-88 ..... (2) 1.6L 4-Cyl. Diesel ...... (3) 60,000
1985-89 ....... 1.8L 4-Cyl. (DOHC) ........ (3) 60,000
1985-93 ....... 1.8L 4-Cyl. (SOHC) ........ (3) 60,000
1990-92 .......... 1.8L 4-Cyl. ............ (3) 60,000
1993-96 .......... 2.0L 4-Cyl. ............ (3) 60,000
Golf (Canadian)
1985-92 ..... (2) 1.6L 4-Cyl. Diesel ...... (3) 60,000
1993 ............. 1.8L 4-Cyl. ............ (3) 60,000
GTI
1983-84 ..... (2) 1.6L 4-Cyl. Diesel ...... (3) 60,000
(2) 1.6L 4-Cyl. Turbo Diesel ... (3) 60,000
1.7L 4-Cyl. ............ (3) 60,000
1.8L 4-Cyl. ............ (3) 60,000
1985-89 .......... 1.8L 4-Cyl. (DOHC) ..... (3) 60,000
1983-92 .......... 1.8L 4-Cyl. (SOHC) ..... (3) 60,000
1990-92 .......... 1.8L 4-Cyl. ............ (3) 60,000
1990-96 .......... 2.0L 4-Cyl. ............ (3) 60,000
GTI (Canadian)
1993 ............. 2.0L 4-Cyl. ............ (3) 60,000
Jetta
1980 ............. 1.6L 4-Cyl. ............ (3) 60,000
1981-92 ........ (2) 1.6L 4-Cyl.
Diesel & Turbo Diesel ....... (3) 60,000
1983-84 .......... 1.7L 4-Cyl. ............ (3) 60,000
1.8L 4-Cyl. ............ (3) 60,000
1985-89 ....... 1.8L 4-Cyl. (DOHC) ........ (3) 60,000
1983-92 ....... 1.8L 4-Cyl. (SOHC) ........ (3) 60,000
1990-92 .......... 1.8L 4-Cyl. ............ (3) 60,000
1993-96 .......... 2.0L 4-Cyl. ............ (3) 60,000
Jetta GLI
1990-92 .......... 2.0L 4-Cyl. ............ (3) 60,000
Passat
1990-96 .......... 2.0L 4-Cyl. ............ (3) 60,000
Passat (Canadian)
1993 ............. 1.8L 4-Cyl. ............ (3) 60,000
Quantum
1981-86 ........ (2) 1.6L 4-Cyl.
Diesel & Turbo Diesel ....... (3) 60,000
1981-84 .......... 1.7L 4-Cyl. ............ (3) 60,000
1984-85 .......... 2.1L 5-Cyl. ............ (3) 60,000
1983-88 .......... 2.2L 5-Cyl. ............ (3) 60,000
1985-86 .......... 1.8L 4-Cyl. ............ (3) 60,000
Rabbit
1974-79 .......... 1.5L 4-Cyl. ............ (3) 60,000
1.6L 4-Cyl. ............ (3) 60,000

INTERFERENCE VERIFICATION CHECK FOR OHC ENGINE
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 09:46PM
1976-80 ..... (2) 1.5L 4-Cyl. Diesel ...... (3) 60,000
1981-84 ........ (2) 1.6L 4-Cyl.
Diesel & Turbo Diesel ....... (3) 60,000
1983-84 .......... 1.7L 4-Cyl. ............ (3) 60,000
1.8L 4-Cyl. ............ (3) 60,000
Scirocco
1976-79 .......... 1.5L 4-Cyl. ............ (3) 60,000
1976-80 .......... 1.6L 4-Cyl. ............ (3) 60,000
1983-84 .......... 1.7L 4-Cyl. ............ (3) 60,000
1.8L 4-Cyl. ............ (3) 60,000
1985-89 ....... 1.8L 4-Cyl. (DOHC) ........ (3) 60,000
1.8L 4-Cyl. (SOHC) ........ (3) 60,000
Scirocco (Canadian)
1989 .......... 1.8L 4-Cyl. (DOHC) ........ (3) 60,000
1.8L 4-Cyl. (SOHC) ........ (3) 60,000
(1) - Other interference engine applications may exist which
are not indicated here.
(2) - Interference engine. Check for possible damage to
piston(s) or valve(s) if there has been a timing belt
failure.
(3) - Although the vehicle manufacturer does not recommend a
specific scheduled maintenance interval, aftermarket
belt manufacturers suggest the belt be replaced at
60,000 mile intervals.
(4) - Vehicle manufacturer recommends replacing all belts at
the same time.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄTIMING BELT INTERFERENCE VERIF. TABLE - LIGHT TRUCKS (1)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Replacement Interval
Application Engine (Miles)
Eurovan (Canadian)
1992-96 .......... 2.5L 5-Cyl. ............ (3) 60,000
Pickup
1980 ....... (2) 1.5L 4-Cyl. Diesel ....... (3) 60,000
1980-83 .......... 1.6L 4-Cyl. ............ (3) 60,000
1981-83 .... (2) 1.6L 4-Cyl. Diesel ....... (3) 60,000
1.7L 4-Cyl. ............ (3) 60,000
Transporter (Canadian)
1992-96 .......... 2.5L 5-Cyl. ............ (3) 60,000
Vanagon
1981-82 .... (2) 1.6L 4-Cyl. Diesel ....... (3) 60,000
(1) - Other interference engine applications may exist which
are not indicated here.
(2) - Interference engine. Check for possible damage to
piston(s) or valve(s) if there has been a timing belt
failure.
(3) - Although the vehicle manufacturer does not recommend a

INTERFERENCE VERIFICATION CHECK FOR OHC ENGINE
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 09:46PM
specific scheduled maintenance interval, aftermarket
belt manufacturers suggest the belt be replaced at
60,000 mile intervals.
(4) - Vehicle manufacturer recommends replacing all belts at
the same time.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE