VOLKSWAGEN CORRADO 1993 Repair Manual

PRE-ALIGNMENT CHECKS
Article Text
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:21PM
ARTICLE BEGINNING
Wheel Alignment
PRE-ALIGNMENT INSPECTION PROCEDURES
PRE-ALIGNMENT CHECKS
Before making wheel alignment adjustment, perform the
following checks:
1) Tires should be equal in size and runout must not be
excessive. Tires and wheels should be in balance, and inflated to
manufacturer's specifications.
2) Wheel bearings must be properly adjusted. Steering linkage
and suspension must not have excessive looseness. Check for wear in
tie rod ends and ball joints.
3) Steering gear box must not have excessive play. Check and
adjust to manufacturer's specifications.
4) Vehicle must be at curb height with full fuel load and
spare tire in vehicle. No extra load should be on vehicle.
5) Vehicle must be level with floor and with suspension
settled. Jounce front and rear of vehicle several times and allow it
to settle to normal curb height.
6) If steering wheel is not centered with front wheels in
straight-ahead position, correct by shortening one tie rod adjusting
sleeve and lengthening opposite sleeve equal amounts.
7) Ensure wheel lug nuts are tightened to torque
specifications.
END OF ARTICLE

RIDING HEIGHT ADJUSTMENT
Article Text
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:22PM
ARTICLE BEGINNING
1993 WHEEL ALIGNMENT
Volkswagen Specifications & Procedures
All Models
* PLEASE READ THIS FIRST *
NOTE: Prior to performing wheel alignment, perform preliminary
visual and mechanical inspection of wheels, tires and
suspension components. See PRE-ALIGNMENT INSTRUCTIONS in
WHEEL ALIGNMENT THEORY/OPERATION article in the
GENERAL INFORMATION section.
RIDING HEIGHT ADJUSTMENT
NOTE: On vehicles with electronic chassis controls, all systems
should be functional before attempting riding height or
wheel alignment adjustment.
Before adjusting alignment, ensure difference in riding
height between left and right sides of vehicle is less than 1" (25.4
mm). Riding height must be checked with vehicle on level floor and
tires properly inflated. Bounce vehicle several times and allow
suspension to settle.
Visually inspect vehicle for signs of abnormal height from
front to rear or side to side. Check passenger and luggage
compartments for extra heavy items and remove if present. If
difference in riding height between left and right sides of vehicle is
NOT less than 1" (25.4 mm), check suspension components and repair or
replace as necessary.
On EuroVan models, measure the distance between bolt head of
upper shock absorber mounting and center of bolt head of lower shock
absorber mounting. If distance measured is not 10.9-11.1" (278-280 mm)
turn torsion bar adjustment bolt until correct riding height is
obtained.
END OF ARTICLE

SCHEDULED SERVICES
Article Text
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:22PM
ARTICLE BEGINNING
1990-94 MAINTENANCE
Volkswagen Maintenance & Service Intervals
Corrado G60 (1990-92)
SLC (1992-94 USA)
VR6 (1992-94 Canada)
* PLEASE READ THIS FIRST *
NOTE: All SERVICE SCHEDULES are listed for normal service
vehicles. If vehicle is operated under severe service
conditions, see SEVERE SERVICE REQUIREMENTS (PERFORM
W/SERVICE SCHEDULES) for items requiring additional
maintenance.
NOTE: This article contains scheduled maintenance service
information. Fluid types and capacities listed with each
service in this article are only those necessary to perform
that scheduled service. For specifications pertaining to
fluid capacities for the entire vehicle, fuse and circuit
breaker identification, wheel and tire size, battery type,
warranty information, or model identification refer to the
MAINTENANCE INFORMATION article in this section.
CAUTIONS & WARNINGS
SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG) - 1995 MODELS
NOTE: See the AIR BAGS article in the ACCESSORIES/SAFETY EQUIPMENT
Section.
Modifications or improper maintenance, including incorrect
removal and installation of the Supplemental Restraint System (SRS),
can adversely affect system performance. DO NOT cover, obstruct or
change the steering wheel horn pad in any way, as such action could
cause improper function of the system. Use only plain water when
cleaning the horn pad. Solvents or cleaners could adversely affect the
air bag cover and cause improper deployment of the system.
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all warnings and service precautions. See
appropriate AIR BAGS article in ACCESSORIES/SAFETY EQUIPMENT.
CAUTION: Disconnect negative battery cable before servicing any air
bag system, steering column or passenger side dash
component. After any repair, turn ignition key to the ON
position from passenger's side of vehicle in case of
accidental air bag inflation

SCHEDULED SERVICES
Article Text (p. 2)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:22PM
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAR WARNING
NOTE: For information on air bag DIAGNOSIS & TESTING or DISPOSAL
PROCEDURES, see AIR BAGS article in the ACCESSORIES/SAFETY
EQUIPMENT Section.
System circuit is grounded by 2 screws beneath the driver's
seat. DO NOT use these screws to ground any other accessory. DO NOT
ground any other components near this system.
AIR CONDITIONING SERVICING (1993 & LATER)
CAUTION: Avoid breathing R-134a refrigerant and PAG lubricant vapors,
exposure may irritate eyes, nose and throat. To remove
R-134a from system use R-134a recycling equipment that meets
SAE J2210 specifications. If accidental system discharge
occurs, ventilate work area before resuming service.
WARNING: R-134a service equipment or vehicle A/C systems SHOULD NOT
be pressure tested or leak tested with compressed air. Some
mixtures of air/R134a have shown to be combustible at
elevated pressures. These mixtures are dangerous and may
cause fire and/or explosions. See AIR CONDITIONING SERVICE
article in GENERAL INFORMATION section.
ANTI-LOCK BRAKE SYSTEM
The anti-lock brake system contains electronic equipment that
can be susceptible to interference caused by improperly installed or
high output radio transmitting equipment. Since this interference
could cause the possible loss of the anti-lock braking capability,
such equipment should be installed by qualified professionals.
On models equipped with anti-lock brake systems, ALWAYS
observe the following cautions:
* DO NOT attempt to bleed hydraulic system without first
referring to the appropriate ANTI-LOCK BRAKE SYSTEM article
in the BRAKES Section.
* DO NOT mix tire sizes. As long as tires remain close to the
original diameter, increasing the width is acceptable.
Rolling diameter must be identical for all 4 tires. Some
manufacturers recommend tires of the same brand, style and
type. Failure to follow this precaution may cause inaccurate
wheel speed readings.
* Use ONLY recommended brake fluids. DO NOT use silicone brake
fluids in an ABS-equipped vehicle.
BATTERY WARNING
WARNING: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is

SCHEDULED SERVICES
Article Text (p. 3)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:22PM
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure. See COMPUTER
RELEARN PROCEDURES article in GENERAL INFORMATION section.
REPLACING BLOWN FUSES
Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical system. Be
sure to use fuse with the correct indicated amperage rating. The use
of an incorrect amperage rating fuse may result in a dangerous
electrical system overload.
BRAKE PAD REPLACEMENT
WARNING: Use caution when checking and/or changing brake pads, some
pads may contain asbestos which can irritate eyes and may
cause other health hazards. A water based solution should be
used to clean brake dust from wheel and brake components.
DO NOT use compressed air to blow off brake dust.
BRAKE SYSTEM
CAUTION: If brake warning light comes on while driving it indicates
a low fluid level or failure in one of the braking
circuits. If the brake pedal can be depressed further than
normal it is an indication that one of the brake circuits
is not functioning. Stop vehicle and check brake reservoir
fluid level. If level is below MIN mark, DO NOT drive
vehicle. Have it towed to a repair shop. If level is
between the MIN and MAX marks, proceed cautiously to a
repair shop.
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning
that brake pads need replacement.
BRAKE PEDAL PRESSURE WITH ENGINE NOT RUNNING
CAUTION: Brake pedal requires extreme pressure to stop the vehicle
when the engine is not running.
CATALYTIC CONVERTER
Continued operation of vehicle with a severe malfunction
could cause converter to overheat, resulting in possible damage to
converter and vehicle.
Any modification to the exhaust system on turbo models, which
reduces exhaust backpressure, will lead to lean fuel mixtures and
excessive spark advance. This could cause serious engine damage.
COOLANT (PROPYLENE-GLYCOL FORMULATIONS)

SCHEDULED SERVICES
Article Text (p. 4)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:22PM
To avoid possible damage to vehicle use only ethylene-glycol
based coolants with a mixture ratio from 44-68% anti-freeze.
DO NOT use 100% anti-freeze as it will cause the formation
of cooling system deposits. This results in coolant
temperatures of over 300ø F (149øC) which can melt plastics.
100% anti-freeze has a freeze point of only -8
ø F (-22øC).
CAUTION: Propylene-Glycol Mixtures has a smaller temperature range
than Ethylene-Glycol. The temperature range (freeze-boil)
of a 50/50 Anti-Freeze/Water Mix is as follows:
Propylene-Glycol -26
ø F (-32øC) - 257ø F (125øC)
Ethylene-Glycol -35
ø F (-37øC) - 263ø F (128øC)
CAUTION: Propylene-Glycol/Ethylene-Glycol Mixtures can cause the
destabilization of various corrosion inhibitors. Also
Propylene-Glycol/Ethylene-Glycol has a different specific
gravity than Ethylene-Glycol coolant, which will result in
inaccurate freeze point calculations.
ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
WARNING: Many solid state electrical components can be damaged by
static electricity (ESD). Some will display a warning label,
but many will not. Discharge personal static electricity by
touching a metal ground point on the vehicle prior to
servicing any ESD sensitive component.
ELECTRIC SHOCK HAZARD
WARNING: Contact with live components of ignition system while
engine is running could lead to a fatal electric shock.
ENGINE OIL
CAUTION: Never use non-detergent or straight mineral oil.
FUEL SYSTEM SERVICE
WARNING: Relieve fuel system pressure prior to servicing any fuel
system component (fuel injection models).
HALOGEN BULBS
Halogen bulbs contain pressurized gas which may explode if
overheated. DO NOT touch glass portion of bulb with bare hands. Eye
protection should be worn when handling or working around halogen
bulbs.
RADIATOR CAP
CAUTION: Always disconnect the fan motor when working near the

SCHEDULED SERVICES
Article Text (p. 5)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:22PM
radiator fan. The fan is temperature controlled and could
start at any time even when the ignition key is in the OFF
position. DO NOT loosen or remove radiator cap when cooling
system is hot.
RADIATOR FAN
WARNING: Keep hands away from radiator fan. Fan is controlled by a
thermostatic switch which may come on or run for up to
15 minutes even after engine is turned off.
WHEELS & TIRES
Only wheels tested and approved by the manufacturer should be
used on models equipped with Air Dam aerodynamic components.
SERVICE POINT LOCATIONSFig. 1: Service Point Locations (1.8L 4-Cylinder)
Courtesy of Volkswagen United States, Inc.

SCHEDULED SERVICES
Article Text (p. 6)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:22PMFig. 2: Service Point Locations (2.8L V6)
Courtesy of Volkswagen United States, Inc.
ADDITIONAL SERVICE INFORMATION

SCHEDULED SERVICES
Article Text (p. 7)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:22PM
CAMSHAFT TIMING BELT SERVICEFig. 3: Aligning 1.8L Timing Marks (8-Valve)
Courtesy of Volkswagen United States, Inc.
NOTE: For more information on camshaft timing belt service refer to
the 1.8L 4-CYL 8-VALVE & 2.0L 4-CYL 16-VALVE
article in the ENGINE MECHANICAL section.
ATTACHING VAG 1551 SCAN TESTER

SCHEDULED SERVICES
Article Text (p. 8)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:22PMFig. 4: Connecting Scan Tester to Data Link Connector (Corrado)
Courtesy of Volkswagen United States, Inc.
NOTE: For more information on scan tester connections
refer to the G - TESTS W/CODES article in
the ENGINE PERFORMANCE section.
INFORMATION LABEL LOCATIONSFig. 5: Information Label Locations
Courtesy of Volkswagen United States, Inc.