VOLKSWAGEN CORRADO 1990 Repair Manual
Manufacturer: VOLKSWAGEN, Model Year: 1990, Model line: CORRADO, Model: VOLKSWAGEN CORRADO 1990Pages: 906, PDF Size: 6.56 MB
Page 761 of 906
SUSPENSION - REAR
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 09:51PM
NOTE: DO NOT remove both suspension struts at same time, as this
would overload axle beam bushings.
Removal
1) With vehicle on floor, remove plastic cap which covers
upper strut retaining nuts. Remove strut retaining nuts. Slowly raise
vehicle until weight is off spring. Remove bolt which retains lower
end of strut shock absorber to axle beam mount. Raise vehicle until
strut can be removed. Place strut assembly in vise.
2) Hold piston rod. Remove strut retaining nut and related
components. See Fig. 1. Remove slotted nut (some models). Remove
spacer and coil spring. If coil spring is to be replaced, ensure paint
stripe color on replacement spring matches original spring color
stripe.
Installation
1) Install protective cap and tube onto shock absorber.
Install rubber buffer with small end downward. Install snap ring and
washer. Place spring into lower seat. Install upper retainer with
spacer sleeve.
2) Tighten slotted nut (some models) which retains piston
rod. Install upper mounting hardware. Tighten piston rod. To complete
installation, reverse removal procedure. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS TABLE at end of article.
SUSPENSION ASSEMBLY
CAUTION: When removing suspension assembly, add weight to rear of
vehicle to prevent tipping resulting from change in center
of gravity.
Removal
1) With vehicle on floor, disconnect upper strut mount. Raise
and support vehicle. Disconnect parking brake at bracket near axle
mount.
2) Disconnect and plug brake lines. Leave flex hose attached
to suspension. Separate brake pressure regulator spring from axle beam
(if equipped). Remove nuts which retain axle beam to body.
NOTE: DO NOT install bolts and nuts fouled with undercoating. With
waxy coating on threads, true tightening torque cannot be
measured. Clean or replace bolts and nuts.
Installation
1) If axle beam mounting has been removed, adjust mounting
pad. See Fig. 2. If pad is not correctly aligned, torsional preload of
mounting bushings will be incorrect.
2) Position rear suspension on body. Install nuts retaining
axle beam to body. Raise wheel. Guide upper end of strut into body
mount.
3) Connect parking brake cables. Connect brake lines. Lower
Page 762 of 906
SUSPENSION - REAR
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 09:51PM
vehicle. Tighten upper strut retaining nuts. Tighten all bolts and
nuts to specification. Bleed brake system.
WHEEL BEARING
Removal (Disc Brakes)
Raise and support vehicle. Remove wheel assembly. Remove
caliper assembly and support it out of work area. Remove dust cap,
cotter pin, hub nut, and thrust washer. Remove brake disc. Using a
long drift, tap bearings, races, and grease seal from disc hub.
Installation
1) Clean hub cavity thoroughly. Using Bearing Race Installer
(VW 432 and VW 411), press inner and outer bearing races into bore.
Lubricate and install inner bearing. Using Seal Installer (VW 295 and
3074), tap grease seal into bore.
2) Install brake disc, outer bearing, thrust washer, and hub
nut. Reverse removal procedure to complete installation. Adjust wheel
bearing. See WHEEL BEARING under ADJUSTMENTS & INSPECTION. Install NEW
cotter pin.
Removal (Drum Brakes)
Raise and support vehicle. Remove wheel assembly. Remove dust
cap, cotter pin, hub nut, and thrust washer. Remove brake drum. Using
a long drift, tap bearings, races, and grease seal from hub.
Installation
1) Clean hub cavity thoroughly. Using Outer Bearing Race
Installer (VW 431 and VW 411), press outer bearing race into bore.
Using Inner Bearing Race Installer (VW 432 and VW 411), press inner
bearing race into bore. Lubricate and install inner bearing. Using
Seal Installer (VW 295 and 3074), tap grease seal into bore.
2) Install brake drum, outer bearing, thrust washer, and hub
nut. Reverse removal procedure to complete installation. Adjust wheel
bearing. See WHEEL BEARING under ADJUSTMENTS & INSPECTION. Install NEW
cotter pin.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Ft. Lbs. (N.m)
Brake Caliper Bolt .................................... 48 (65)
Coil Spring Retainer-To-Piston Rod Nut ................ 11 (15)
Rear Axle Beam Pivot Bushing Bolt ..................... 43 (58)
Rear Axle Mounting Pad-To-Body Bolt ................... 63 (85)
Shock Absorber Slot Nut ............................... 15 (20)
Shock Absorber-To-Axle Beam Nut ....................... 52 (70)
Shock Absorber-To-Body Bolt ........................... 26 (35)
Stub Axle-To-Control Arm Bolt ......................... 44 (60)
Wheel Lug Bolt ....................................... 81 (110)
Page 763 of 906
SUSPENSION - REAR
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 09:51PMÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE
Page 764 of 906
TRANSMISSION REMOVAL & INSTALLATION - A/T
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:51PM
ARTICLE BEGINNING
1990-91 TRANSMISSION SERVICING
Automatic Transmission Removal & Installation
Cabriolet, Corrado, Fox, Golf GTI, Jetta, Passat
CABRIOLET, GOLF, GTI & JETTA
NOTE: For manual transaxle replacement procedures, see appropriate
CLUTCH article in the CLUTCHES Section.
REMOVAL & INSTALLATION
1) Disconnect battery ground cable. Disconnect speedometer
cable from transaxle. Raise and support vehicle. Remove left front
wheel.
2) Support engine from above. Remove left rear transaxle
mount and support. Remove upper transaxle-to-engine bolts. Remove
upper bolts from front engine/transaxle mount.
3) Remove lower bolts on front mount and remove mount. Remove
protective plate from transaxle. Remove torque converter-to-drive
plate bolts.
4) Disconnect accelerator and selector cables from transaxle.
Place mating marks on drive axle flanges and remove left and right
axle shaft flange bolts.
NOTE: If clearance is needed to remove transaxle, separate ball
joint from left side steering knuckle and move axle shaft
away from transaxle.
5) Remove left rear engine mount. Remove starter. Remove
subframe mounting bolts and allow subframe to hang free. Support
transaxle with jack. Remove lower mounting bolt. Lower transaxle. To
install, reverse removal procedure. Adjust accelerator and selector
cables.
CORRADO & PASSAT
NOTE: For manual transaxle replacement procedures, see appropriate
CLUTCH article in the CLUTCHES Section.
REMOVAL & INSTALLATION
1) Disconnect battery ground cable. Remove air ducts to brake
caliper and engine air intake. Disconnect speedometer cable from
transaxle. Remove upper transaxle-to-engine bolts.
2) Disconnect and plug transaxle cooler lines. Support engine
from above. Remove starter. Disconnect accelerator and selector cables
from transaxle. Remove left transaxle mount and support.
3) Remove electrical wiring from transaxle. Remove lower
Page 765 of 906
TRANSMISSION REMOVAL & INSTALLATION - A/T
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 09:51PM
bolts on front mount and remove mount. Place mating marks on drive
axle flanges and remove left and right axle shaft flange bolts.
4) Disconnect right strut-to-spindle bolts. Remove right side
axle. Reconnect strut. Remove protective plate from transaxle. Remove
torque converter-to-drive plate bolts.
5) Slightly lower engine assembly. Support transaxle with
jack. Remove lower transaxle-to-engine mounting bolts. Lower
transaxle. To install, reverse removal procedure. Adjust accelerator
and selector cables.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplications Ft. Lbs. (N.m)
Cabriolet, Golf, GTI & Jetta
Axle Shaft-To-Flange Bolts ................ 33 (45)
Torque Converter-To-Drive Plate Bolts ..... 26 (35)
Transaxle-To-Engine Bolts ................. 55 (75)
Corrado & Passat
Axle Shaft Nut .......................... 195 (265)
Axle Shaft-To-Flange Bolts ................ 33 (45)
Strut-To-Spindle .......................... 70 (95)
Torque Converter-To-Drive Plate Bolts ..... 45 (60)
Transaxle-To-Engine
M10 Bolts ............................... 45 (60)
M12 Bolts ............................... 60 (80)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE
Page 766 of 906
TRANSMISSION SERVICING - A/T
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:51PM
ARTICLE BEGINNING
1990-91 TRANSMISSION SERVICING
Automatic Transmission
Cabriolet, Corrado, Golf, GTI, Jetta, Passat
IDENTIFICATION
VOLKSWAGEN AUTOMATIC TRANSMISSION APPLICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄModel Transmission
Cabriolet, Golf,
GTI & Jetta ................ Model 010 Transmission
Corrado & Passat ............. Model 096 Transmission
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ LUBRICATION SERVICE INTERVALS
Check fluid level at each oil change. Change fluid every 30,
000 miles under severe driving conditions. Replace ATF filter on
Corrado and Passat every 30,000 miles (if equipped).
CHECKING LUBRICANT FLUID LEVEL
TRANSMISSION
Park vehicle on level surface, with transmission at normal
operating temperature. Set selector lever to Park or Neutral. Apply
parking brake. Allow engine to idle. Remove dipstick, wipe clean, and
reinsert. Remove dipstick. Fluid level should be between marks on
dipstick.
NOTE: Normal transmission fluid color on late production vehicles
is Red/Brown.
FINAL DRIVE (EXCEPT CORRADO & PASSAT)
Place vehicle on level surface. Fluid level should be up to
edge of fill hole on side of case.
FINAL DRIVE (CORRADO & PASSAT)
Place vehicle on level surface. Remove speedometer drive
shaft. Wipe shaft clean. Reinsert and again remove shaft. Fluid level
should be between MIN and MAX marks on shaft.
RECOMMENDED LUBRICANT FLUID
Page 767 of 906
TRANSMISSION SERVICING - A/T
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 09:51PM
TRANSMISSION
Use Dexron or Dexron-II ATF.
FINAL DRIVE
Use G50 or SAE 75WÄÄ90.
FLUID CAPACITY
TRANSMISSION REFILL CAPACITIES TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Refill Dry Fill
Application Qts. (L) Qts. (L)
Corrado & Passat ....... 3.2 (3.0) ...... 5.9 (5.6)
Except Corrado &
Passat ................ 3.2 (3.0) ...... 6.4 (6.0)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄFINAL DRIVE REFILL CAPACITIES TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄModel Qts. (L)
All Except Vanagon .......................... .8 (.8)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ DRAINING & REFILLING
1) Remove transmission protection plate (if necessary).
Remove rear pan bolts. Loosen front pan bolts. Carefully lower pan to
drain as much fluid as possible. Remove oil pan. Pour out remaining
fluid. Remove filter. Clean oil pan in solvent. Dry pan with
compressed air.
2) Install new filter. On all but Corrado and Passat, tighten
filter retaining screws to 27 INCH lbs. (3 N.m). On Corrado and
Passat, tighten filter retaining screws to 71 INCH lbs (8 N.m).
3) Install oil pan with new gasket. On all models but Corrado
and Passat, tighten oil pan bolts to 15 ft. lbs. (20 N.m). On Corrado
and Passat, tighten oil pan bolts to 89 INCH lbs. (10 N.m).
4) Install protection plate if it was removed. Tighten bolts
to 18 ft. lbs. (25 N.m). Add 3.2 qts. (3.0L) transmission fluid. Check
fluid level. Add if necessary.
SECOND BRAKE BAND ADJUSTMENTS
CABRIOLET, GOLF, GTI & JETTA
1) Adjust second brake band with transmission in a horizontal
position only. Loosen adjuster screw lock nut. Tighten brake band
adjustment screw to 89 INCH lbs. (10 N.m). See Fig. 1.
Page 768 of 906
TRANSMISSION SERVICING - A/T
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 09:51PMFig. 1: Adjusting Second Brake Band
Courtesy of Volkswagen United States, Inc.
2) Loosen adjustment screw, then retighten to 44 INCH lbs. (5
N.m). Back off 2 1/2 turns. Hold adjustment screw stationary while
tightening lock nut to 15 ft. lbs. (20 N.m).
SELECTOR LEVER CABLE ADJUSTMENTS
CABRIOLET, GOLF, GTI & JETTA
Set transmission selector lever to Park. Loosen nut for
clamping pin which retains selector cable to operating lever on
transmission. Ensure selector lever and transmission operating lever
are in Park. Tighten cable clamp nut to 71 INCH lbs. (8 N.m).
CORRADO & PASSAT
Set transmission selector to Park. Loosen screw at gear lever
shaft. Set gear lever in Park. Ensure detent engages parking lock.
Tighten screw to 15 ft. lbs. (20 N.m) on Corrado, or to 18 ft. lbs.
(25 N.m) on Passat.
THROTTLE CABLE ADJUSTMENTS
NOTE: Adjust accelerator linkage so that the operating lever on
transmission is against stop when throttle valve is closed.
CABRIOLET, GOLF, GTI & JETTA
1) Engine must be at operating temperature and turned off.
Set transmission gear selector to Park. Loosen adjustment nut and lock
nut on throttle cable at transmission. Disconnect throttle cable from
transmission. See Fig. 2.Fig. 2: Adjusting Trans. Throttle Cable (Model 010 Trans.)
Courtesy of Volkswagen United States, Inc.
Page 769 of 906
TRANSMISSION SERVICING - A/T
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 09:52PM
2) Loosen lock nuts on throttle cable support bracket. Push
throttle cable sleeve in direction of arrow until there is no play.
See Fig. 3.Fig. 3: Adjusting Throttle Cable (Model 010 Transmission)
Courtesy of Volkswagen United States, Inc.
3) Throttle valve must remain closed and
accelerator/transmission linkage must be in closed position.
4) Turn lock nut No. 1 against support bracket. Tighten lock
nut No. 2 to 18-89 INCH lbs. (2-10 N.m). Install accelerator cable
onto transmission.
5) Press and hold accelerator pedal against stop. Working at
transmission, push transmission operating lever against kickdown
adjustment nuts.
6) Turn adjustment nut until all slack is removed from cable.
Release accelerator pedal. Ensure transmission operating lever rests
against kickdown stop. Tighten lock nut.
NEUTRAL SAFETY SWITCH ADJUSTMENTS
Neutral safety switch is located in shift console. Remove
console cover. Adjust switch so that engine starts in Park and Neutral
positions only.
END OF ARTICLE
Page 770 of 906
TRANSMISSION SERVICING - M/T
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:52PM
ARTICLE BEGINNING
1990-91 TRANSMISSION SERVICING
Manual Transmission
Cabriolet, Corrado, Fox, Golf, GTI, Jetta, Passat, Vanagon
IDENTIFICATION
MANUAL TRANSAXLE APPLICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄModel Transaxle
Cabriolet ................ 5-Speed - 020 Transaxle
Corrado .................. 5-Speed - 02A Transaxle
Fox ...................... 4-Speed - 014 Transaxle
Golf ..................... 5-Speed - 020 Transaxle
GTI ...................... 5-Speed - 020 Transaxle
Jetta .................... 5-Speed - 020 Transaxle
Passat ................... 5-Speed - 02A Transaxle
Vanagon ................ 4-Speed - 091 Transaxle
Vanagon Syncro ........... 5-Speed - 094 Transaxle
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ LUBRICATION SERVICE INTERVALS
No oil changes are required.
CHECKING LUBRICANT FLUID LEVEL
Manufacturer states that fluid level does not have to be
checked, and does not specify a procedure for doing so.
RECOMMENDED LUBRICANT FLUID
Use API GL-4, SAE 80W or 80W-90.
FLUID CAPACITY
TRANSAXLE REFILL CAPACITIES TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄTransaxle Qts. (L)
02A ....................................... 2.1 (2.0)
014 ....................................... 1.8 (1.7)
020 ....................................... 2.1 (2.0)
091 ....................................... 3.2 (3.0)
094 ....................................... 4.7 (4.5)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ