VOLKSWAGEN CORRADO 1990 Repair Manual

MIRRORS - POWER
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 09:49PM
from falling out.
Removal & Installation
1) Disconnect battery ground cable. Lower window. Remove
control knob and boot. Remove door trim, and loosen moisture barrier
in area of rearview mirror control. Remove lock nut. Unplug electrical
connector.
2) Pivot mirror inward, and remove mounting screw. Pivot
mirror outward, and remove second mounting screw. Remove mirror with
base and control. To install, reverse removal procedure.
POWER MIRROR ASSEMBLY (GOLF GL, GTI, JETTA & JETTA GLI)
CAUTION: Always wear protective gloves while handling mirror glass
in case of accidental breakage. Hold glass to prevent it
from falling out.
Removal & Installation
1) Disconnect battery ground cable. Remove mirror glass and
electrical wires. See MIRROR GLASS under REMOVAL & INSTALLATION.
Remove mirror adjustment motor securing screws and motor. Disconnect
electrical wires. Carefully pry mirror adjustment switch from door
panel. Unplug electrical connector.
2) Remove door trim panel and protective cover from door near
mirror wire connectors. Disconnect terminals. To install, connect
adjustment motor wires according to marked color identification.
Reverse removal procedure to complete installation.
POWER MIRROR ASSEMBLY (VANAGON)
CAUTION: Always wear protective gloves while handling mirror glass
in case of accidental breakage. Hold glass to prevent it
from falling out.
Removal & Installation
1) Disconnect battery ground strap. Pry out and disconnect
electric mirror switch from door trim panel. See Fig. 8. Remove door
trim panel, and carefully pull back plastic moisture barrier. Cut tie
wraps securing wiring harness to door. See Fig. 9. Open harness far
enough to expose and label individual wires. Remove labeled wires from
plug connector.
2) Pry off plastic cap at base of mirror bracket, and remove
3 bracket securing screws. See Fig. 10. Remove mirror assembly with
wiring harness. To install, reverse removal procedure, ensuring seal
is positioned for proper fit and wire harness is secured to door frame
with tie wraps. See Fig. 11. Check mirror for proper function.

MIRRORS - POWER
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 09:49PMFig. 8: Disconnecting Electric Mirror Switch (Vanagon)
Courtesy of Volkswagen United States, Inc.Fig. 9: Securing Wiring Harness (Vanagon)
Courtesy of Volkswagen United States, Inc.Fig. 10: Removing Mirror Bracket Screws (Vanagon)
Courtesy of Volkswagen United States, Inc.

MIRRORS - POWER
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 09:49PMFig. 11: Installing Mirror Assembly (Vanagon)
Courtesy of Volkswagen United States, Inc.
WIRING DIAGRAMS
See appropriate chassis wiring diagram in WIRING DIAGRAMS.
END OF ARTICLE

N - REMOVE/INSTALL/OVERHAUL
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:49PM
ARTICLE BEGINNING
1990 ENGINE PERFORMANCE
Removal, Overhaul & Installation
Volkswagen; Cabriolet, Corrado, Fox, Golf GL/GTI,
Jetta, Vanagon
INTRODUCTION
Removal, overhaul and installation procedures are covered in
this article. If component removal and installation is primarily an
unbolt and bolt-on procedure, only a torque specification may be
furnished. See TORQUE SPECIFICATIONS at the end of this article.
REMOVAL & INSTALLATION
DISTRIBUTOR (DIGIFANT)
Removal (AFC-Digifant II)
Turn engine crankshaft to TDC. Remove distributor cap. Rotor
should point to No. 1 cylinder mark on edge of distributor housing.
Index mark the distributor housing to the crankcase relation. Remove
distributor hold-down clamp and bolt. Remove distributor assembly.
Installation
Align rotor with No. 1 cylinder mark on edge of distributor
housing. Install distributor and align housing to index mark made on
crankcase. Install distributor hold-down clamp and bolt. Install
distributor cap. Check timing. Tighten hold-down bolt to
specification. See TORQUE SPECIFICATIONS.
DISTRIBUTOR (CIS SYSTEMS)
Removal (CIS-E & CIS-E Motronic)
1) Turn engine crankshaft to TDC. Marking on vibration
dampener pulley must align with drive belt guard pointer. Marking on
cam shaft gear sprocket must align with cylinder head cover.
2) Remove distributor cap and mark position of rotor. Rotor
should be pointing to No. 1 cylinder in distributor firing sequence.
Mark position of distributor housing for installation reference.
Remove distributor hold-down clamp and bolt. Remove distributor
assembly, noting position of rotor when distributor shaft gear is
disengaged from driving gear.
Installation
1) Align oil pump drive pinion lug parallel to crankshaft.
Set rotor pointing toward mark made when distributor was disengaged
from drive gear.
2) Install distributor. Rotor should now point to mark made
for No. 1 cylinder in distributor firing sequence. Align mark for

N - REMOVE/INSTALL/OVERHAUL
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 09:49PM
distributor housing and install distributor hold-down clamp and bolt.
Install distributor cap. Check timing. Tighten hold-down bolt to
specification. See TORQUE SPECIFICATIONS.
AIRFLOW SENSOR PLATE
Removal & Installation
1) Remove air filter and unscrew stop bracket. Using heat
gun, heat locking compound on fastening bolt. Remove bolt slowly. DO
NOT damage threads. Clean locking compound from bolt hole threads.
2) Install airflow sensor plate. Ensure 5 dimple marks are
up. Lightly tighten self-locking screw. Ensure sensor plate is
centered and rest position is correct. To complete installation,
reverse removal procedure. See TORQUE SPECIFICATIONS.
AIRFLOW SENSOR POTENTIOMETER
Removal & Installation
Remove differential pressure regulator. Remove insulating
compound covering mounting screws. Remove potentiometer. DO NOT touch
or damage slide contact and conductor. To install, reverse removal
procedure. See TORQUE SPECIFICATIONS. Adjust potentiometer. See D -
ADJUSTMENTS article.
FUEL DISTRIBUTOR (1.8L ONLY)
CAUTION: Fuel system pressure must be relieved before removing or
disconnecting any fuel lines. Wipe up all spilled fuel
BEFORE continuing service.
Removal
1) Disconnect battery and remove air cleaner. Disconnect all
fuel and injector lines from fuel distributor. Plug fuel supply and
return lines. Catch any spilled fuel.
2) Disconnect wiring from differential pressure regulator.
Remove screws holding fuel distributor to airflow sensor housing.
Remove fuel distributor by turning back and forth while lifting up.
Air Sensor Plate Rest Position
Upper edge of sensor plate must be .070-080" (1.80-2.10 mm)
below lower edge of sensor cone. See Fig. 1. If rest position is
incorrect, raise sensor plate. Open or close wire clip to change
position of sensor plate. DO NOT bend leaf spring.Fig. 1: Identifying Sensor Plate Rest Position
Courtesy of Volkswagen United States, Inc.

N - REMOVE/INSTALL/OVERHAUL
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 09:49PM
Centering Sensor Plate & Lever
1) Check sensor plate for centered position in airflow sensor
housing. See Fig. 2. If plate binds on housing or is off-center,
remove 6-mm bolt holding plate to lever. Coat bolt with locking
compound and install finger tight.
2) Use Centering Gauge (US 1109) or .004" (.10 mm) feeler
gauge to set plate an equal distance from sensor housing. If plate
cannot be centered, remove airflow sensor housing.
3) Turn housing upside-down and remove counterweight-to-
sensor lever bolt. Coat bolt with locking compound and install finger
tight. Center sensor plate lever in housing and tighten bolt. Complete
centering of plate.Fig. 2: Adjusting Sensor Plate Lever On Airflow Sensor Housing
Courtesy of Volkswagen United States, Inc.
Checking Sensor Plate Free Play
1) Free play is measured between control piston and adjusting
lever. To ensure Differential Pressure Regulator (DPR) current is 4-16
mA, sensor plate lever must be positioned correctly. Measure free play
on side of sensor cone closest to fuel distributor. See Fig. 3.
2) Crank starter motor for 10 seconds to develop fuel
pressure. Lift sensor plate slightly until resistance is felt. Minimum
clearance is any noticeable free play. Maximum clearance is .083" (2.1
mm) up to sensor cone.
3) If free play clearance is incorrect, remove fuel
distributor. Check basic adjustment of sensor plate lever. Install
fuel distributor and repeat free play clearance check. If still
incorrect, adjust sensor plate clearance with control piston stop
screw.

N - REMOVE/INSTALL/OVERHAUL
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 09:49PMFig. 3: Checking Sensor Plate Free Play
Courtesy of Volkswagen United States, Inc.
Sensor Plate Lever Adjustment
1) Check basic adjustment of sensor plate lever. With fuel
distributor removed from airflow sensor housing, measure distance
between roller on sensor plate lever and contact points of fuel
distributor on top of airflow sensor housing.
2) Use a depth gauge or vernier caliper for measuring
distance. See Fig. 2. Distance should be .74-.75" (18.9-19.1 mm). If
distance is out of specified range, correct it by adjusting mixture
screw.
Installation
1) Lightly lubricate new sealing "O" ring and mount on fuel

N - REMOVE/INSTALL/OVERHAUL
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 09:49PM
distributor. Install fuel distributor. See TORQUE SPECIFICATIONS for
tightening specifications. Connect all fuel lines except those to fuel
injectors. Check sensor plate adjusting lever and fuel distributor
control piston for smooth operation.
2) Remove fuel pump relay and bridge fuel pump circuit. Use
Jumper Switch (US 4480/3) in place of fuel pump relay. When pressure
has built up, turn off fuel pump. Move sensor plate from rest position
to end of travel.
3) Uniform resistance should be felt during entire movement.
No resistance should be felt during entire movement. No resistance
should be felt on quick return to rest position. Connect injector
lines. Install fuel pump relay. Start engine and check for leaks.
INJECTORS (DIGIFANT)
CAUTION: Fuel system pressure must be relieved before removing
injectors. Wipe up all spilled fuel BEFORE continuing
service.
Removal (AFC-Digifant II)
Disconnect negative battery cable. Disconnect main electrical
connector from fuel rail. Remove idle stabilizer valve. Loosen and
remove both hoses on each end of fuel rail. Remove fuel pressure
regulator and mounting bracket. Remove fuel rail mounting bolts. Pry
off injector mounting clips. Disconnect injector electrical
connectors. Remove fuel rail. Remove each injector from its insert.
Installation
To install injectors, reverse removal procedures. Use new "O"
rings when installing injectors. Replace hose clamps if necessary. See
TORQUE SPECIFICATIONS table at end of this article. Check for fuel
leaks.
INJECTORS (CIS SYSTEMS)
Removal (CIS-E & CIS-E Motronic)
Remove injectors from inserts in cylinder head with fuel
lines attached. Using 12-mm or 13-mm hex wrench, remove inserts from
head. Use 2 wrenches to remove injectors from fuel lines.
Installation
To install, reverse removal procedures. Use 2 wrenches when
tightening injector lines to injectors. Use new "O" rings lightly
lubricated. On models with 2-piece inserts, replace insert sealing
washer (against head) and use sealing compound on upper insert
threaded portion. See TORQUE SPECIFICATIONS.
OXYGEN (O2) SENSOR
Removal & Installation
Oxygen (O2) sensor is mounted in the exhaust pipe in front of
catalytic converter. Disconnect permanent pigtail from sensor. Ensure

N - REMOVE/INSTALL/OVERHAUL
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 09:49PM
sensor is free of contaminants, avoid using any cleaning solvents.
Sensor may be difficult to remove when engine temperature is less than
118øF (48øC). Always use anti-seize compound on threads before
installation. Tighten sensor to specification. See
TORQUE SPECIFICATIONS.
SUPERCHARGER (CORRADO)
Removal & Installation
Information on removal and installation is not available from
manufacturer. See Fig. 4 for exploded view of supercharger assembly.Fig. 4: Supercharger Assembly Exploded View (Corrado)
Courtesy of Volkswagen United States, Inc.
THROTTLE VALVE HOUSING (TVH)
Removal & Installation
1) Disconnect accelerator cable from linkage. Disconnect
return spring on TVH. Remove cruise control connecting rod on TVH (if
equipped). Pull off vacuum hoses. Remove TVH mounting nuts.
2) Disconnect throttle valve switch. Remove 2 TVH-to-metallic
front vibration mounts nuts. Disconnect fuel return hose from pressure
regulator. Lift sensor housing upward and remove TVH. Remove gasket.
3) To install, reverse removal procedure. Ensure all surfaces
are clean and mate correctly. Use new gaskets when assembling. Adjust
accelerator linkage and idle speed. See TORQUE SPECIFICATIONS.
TORQUE SPECIFICATIONS

N - REMOVE/INSTALL/OVERHAUL
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 09:49PM
TORQUE SPECIFICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Ft. Lbs. (N.m)
AFC-Digifant II
Fuel Injector Inserts .................................... 15 (20)
Fuel Pressure Regulator Mounting Bolt .................... 11 (15)
Intercooler Bracket Mounting Bolts (Corrado) ............. 15 (20)
Knock Sensor ............................................. 15 (20)
Oxygen Sensor ............................................ 37 (50)
Supercharger Mounting Bolts (Corrado) .................... 18 (24)
Supercharger Pulley Bolt (Corrado) ....................... 33 (45)
Supercharger To Silencer Assembly Bolts (Corrado) ........ 18 (24)
Throttle Valve Body Mounting Bolts ....................... 15 (20)
CIS-E & CIS-E Motronic
Distributor Hold-Down Bolt (Fox) ......................... 18 (24)
Fuel Injection Valve Fuel Line Nut ....................... 18 (24)
Fuel Return Line Fitting ................................. 15 (20)
Fuel Supply Line Union Bolts ............................. 15 (20)
Intake Manifold Temperature Sensor (Jetta GLi 2.0L) ...... 15 (20)
Oxygen Sensor ............................................ 37 (50)
Thermo Time Switch (CIS-E) ............................... 22 (30)
Throttle Valve Housing Mounting Bolts .................... 15 (20)
INCH Lbs. (N.m)
AFC-Digifant II
Fuel Rail Mounting Bolts ................................. 87 (10)
Idle Stabilizer Valve Mounting Nuts ...................... 87 (10)
Intercooler Mounting Bolts (Corrado) ..................... 87 (10)
Supercharger Air Hose Mounting Bolts (Corrado) ........... 87 (10)
CIS-E & CIS-E Motronic
Auxiliary Air Regulator Mounting Bolts ................... 87 (10)
Cold Start Valve Mounting Bolts .......................... 87 (10)
Coolant Temperature Sensor ............................... 87 (10)
Distributor Hold-Down Bolt (Jetta GLi) ................... 87 (10)
EGR Valve Mounting Bolts ................................. 87 (10)
Fuel Distributor Mounting Bolts ......................... 30 (3.4)
Fuel Line Fittings ....................................... 87 (10)
Test Port Plug ........................................... 87 (10)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE