1990 VOLKSWAGEN CORRADO Repair Manual

STARTER - BOSCH
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
Faulty Ammeter ........................... Test/Replace Ammeter
NOISY Defective Battery ....................... Replace Battery
Defective Alternator ................... Test/Repair Alternator
Defective Regulator ..................... Test/Repair RegulatorÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ ON-VEHICLE TESTING
STARTER DOES NOT CRANK ENGINE
1) Ensure battery is fully charged. Make sure electrical and
ground connections are clean and tight. With ignition switch in START
position, measure voltage at spade terminal of starter solenoid.
Reading should be at least 8 volts (9.5 volts on Fox). If so, check
engine for mechanical problems. If voltage is not as specified, go to
next step.
2) Measure voltage at ignition switch. If reading is at least
8 volts (9.5 volts on Fox), check wiring between ignition switch and
starter solenoid. If voltage is not as specified, replace ignition
switch.
3) Measure voltage at field (starter) terminal of starter
solenoid. If reading is 8 volts or more, repair or replace starter. If
reading is less than 8 volts, replace starter solenoid.
NOTE: On vehicles with automatic transmission, also check
park/neutral switch.
STARTER CRANKS TOO SLOWLY
Ensure engine crankcase is filled with recommended viscosity
oil. Check charging system to ensure battery is fully charged. Make
sure electrical and ground connections are clean and tight. If starter
still turns slowly, repair or replace starter.
VOLTAGE DROP TEST
Starter Main Terminal
Connect a voltmeter between starter main terminal and starter
body. Disconnect ignition coil positive terminal and operate starter.
Voltage reading should not be more than 1.0 volt less than battery
voltage. If a larger voltage drop is indicated, circuit between
battery and starter terminal may be defective.
Main Starter Case
Connect a voltmeter between positive battery terminal and
starter motor "M" terminal. With ignition off, operate starter for 2-3
seconds. Battery voltage should be present, then drop to less than one
volt. If voltage is greater than specification, high resistance may be
present in circuit. Go to ACROSS SOLENOID SWITCH test.
Across Solenoid Switch
Connect a voltmeter between 2 starter solenoid terminal stud

STARTER - BOSCH
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
connections. With ignition disconnected, operate starter for 2-3
seconds and note meter reading. Initially, battery voltage should be
present, then voltage should drop to less than .5 volts. If voltage is
not as specified, check for damaged switch or loose or dirty
connections. If high resistance is present, terminal may be loose or
corroded.
Ground Return Line
Connect a voltmeter between battery ground terminal and
starter main housing. With ignition off, operate starter for 2-3
seconds. If ground is okay, voltage reading should be less than .5
volt. If reading is .6 volt or more, high resistance is present in
ground return side of circuit.
BENCH TESTING
STARTER SOLENOID
1) Remove bridge strap connecting solenoid to motor. Check
windings by connecting a 12-volt battery operated test light between
solenoid main terminal STA and solenoid body. If light illuminates,
both windings are satisfactory.
2) Ensure that contacts open and close satisfactorily by
connecting 12-volt battery and a high wattage test light between main
solenoid terminals. Test light should not illuminate.
3) Close switch by energizing solenoid windings. Solenoid
should be heard to operate and closing of solenoid contacts will be
indicated by test light illuminating to full brilliance. On opening
switch, test light should go out.
STARTER LOAD (LOCK) TEST
With starter on test bench, lock starter drive pinion.
Voltmeter should read 4.5 volts and ammeter should read 700-800 amps.
STARTER NO-LOAD TEST
With starter on test bench, operate starter and check
ammeter, voltage, and RPM. Readings should be within specification.
See STARTER NO-LOAD TEST SPECIFICATIONS table.
STARTER NO-LOAD TEST SPECIFICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄVolts Amps RPM
11.5 ......................... 65-95 ........................ 6500
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ VANAGON R & I
Removal & Installation
1) Disconnect battery ground strap. Before raising vehicle,

STARTER - BOSCH
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
remove upper starter mounting bolt. Release handbrake (to allow axle
rotation) and raise vehicle on hoist.
2) Disconnect right rear axle from transmission and wire
aside. Cover exposed CV joint with plastic bag to prevent entry of
dirt or other foreign material.
3) Loosen clamp securing cooling hoses to chassis. Wire hoses
aside. Remove bolt "A" from differential lock servo. Loosen bolt "B"
and withdraw as far as possible. Lack of clearance prevents complete
removal of bolt "B". See Fig. 1.
NOTE: Nuts are welded to bracket. DO NOT attempt to loosen.Fig. 1: Removing Differential Lock Servo (Vanagon)
Courtesy of Volkswagen United States, Inc.
4) Push back protective sleeve and drive out spring pin. With
bolt "B" withdrawn as far as possible, give servo a slight upward
twist and remove from bracket. See Fig. 1.
5) Remove circlip, bracket securing bolts and bracket. See
Fig. 2.Fig. 2: Removing Differential Lock Servo Bracket (Vanagon)
Courtesy of Volkswagen United States, Inc.

STARTER - BOSCH
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 09:51PM
6) Disconnect wires from starter solenoid. Remove lower
mounting nut, push up slightly on starter and remove. See Fig. 3. To
install, reverse removal procedure.Fig. 3: Removing Starter (Vanagon)
Courtesy of Volkswagen United States, Inc.
ALL MODELS EXCEPT VANAGON R & I
Removal & Installation
Disconnect negative battery cable. Support
engine/transmission assembly with Support Beam (VW 10-222). On all
models except Fox, add a Leg Set (VW 10-2224/1) to support beam. On
all models, remove engine mount bolts, nut, and clamp screw (next to
exhaust manifold flange). Remove engine mount. Disconnect wiring and
remove starter. To install, reverse removal procedure. See Fig. 4.Fig. 4: Removing Starter (Except Vanagon)
Courtesy of Volkswagen United States, Inc.

STARTER - BOSCH
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 09:51PM
OVERHAUL
For overhaul, see exploded view of typical Bosch starter. See
Fig. 5.Fig. 5: Exploded View of Bosch Starter (Typical)
Courtesy of Volkswagen United States, Inc.

STARTER - BOSCH
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 09:51PM
STARTER SPECIFICATIONS
STARTER SPECIFICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Specification
Armature
Runout ............................... .002" (.05mm)
End Play ............................. .002" (.05mm)
Cold Cranking
Test Voltage .................................... 12
Minimum Voltage .................................. 9
Amps ............................................ 90
Minimum RPM ................................... 1500
Solenoid Hold-In
Winding Voltage .................... 4 Volts (Min.)
Solenoid Pull-In
Winding Voltage ................................. 7
Commutator Runout ..................... .0004" (.01mm)
Cranking Voltage ........................ 9 Volts Min.
Starter Current Draw ................... 170 Amps Max.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Ft. Lbs. (N.m)
Starter-To-Block Bolts
All Except Vanagon .................... 32.5-44.3 (44-60)
Vanagon ......................................... 21 (28)
Starter-To-Block Bolts (1992)
Cabriolet, Golf, GTI & Jetta
A/T ............................................. 14 (19)
M/T ............................................. 43 (58)
Corrado, Fox & Passat ............................ 44 (60)
INCH LBS. (N.m)
Solenoid Bolts .................................. 96 (10.8)
Through Bolts .................................... 54 (6.1)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE

STEERING COLUMN
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
1990-92 STEERING
Volkswagen Steering Columns
Cabriolet, Corrado, Fox, Golf, GTI, Jetta, Passat
WARNING: To aviod injury from accidental AIR BAG deployment, read and
carefully follow all WARNINGS and SERVICE PRECAUTIONS.
NOTE: For information on air bag DIAGNOSIS & TESTING or DISPOSAL
PROCEDURES, See appropriate AIR BAG article in the
ACCESSORIES/SAFETY EQUIPMENT Section
DESCRIPTION
Swing-away steering column is held by a clamp and leaf
spring. On impact, the "U" joint shaft pushes steering column against
the leaf spring. The spring allows the column to disengage and swing
away.
CAUTION: Applying excessive pressure or causing impact to mainshaft
during service may cause the column to disengage.
REMOVAL & INSTALLATION
AIR BAG
WARNING: On Cabriolet with Supplemental Restraint System (air bag),
remove air bag from vehicle before working on steering
column. Follow all WARNINGS and SERVICE PRECAUTIONS to
prevent injury from accidental air bag deployment. See AIR
BAG article in the ACCESSORY/SAFETY EQUIPMENT.
Removal & Installation (Cabriolet)
1) Disconnect negative battery cable. Wait at least 20
minutes for air bag capacitor to discharge. Remove 2 Torx screws (No.
30) from back of steering wheel.
2) Carefully tilt air bag down away from steering wheel.
Disconnect electrical wire from back of air bag unit. Remove air bag
unit from vehicle. DO NOT store air bag unit on its vinyl side. Store
air bag unit on its metal housing.
3) To install, reverse removal procedure. Install new Torx
screws to hold air bag unit in steering wheel. Tighten Torx screws to
89 INCH lbs. (10 N.m).
STEERING WHEEL & HORN PAD
Removal & Installation
1) Disconnect negative battery cable. On Corrado and Passat,
lift cover from bottom, then pull cover away from steering wheel. On

STEERING COLUMN
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
Corrado and Passat, spread horn button locating lugs, then separate
contact plates. On other models, pry center cover from steering wheel.
2) Disconnect horn wiring. Ensure steering wheel is in
straight-ahead position. Mark shaft and wheel for reassembly
reference. Remove retaining nut and washer. Pull steering wheel from
shaft. Reverse removal procedure to install.
TURN SIGNAL SWITCH
Removal & Installation
Remove steering wheel. See STEERING WHEEL & HORN PAD. Remove
retaining screws. Unplug harness connector. Remove turn signal switch.
To install, reverse removal procedure.
WINDSHIELD WIPER SWITCH
Removal & Installation
Remove steering wheel. See STEERING WHEEL & HORN PAD. Remove
turn signal switch. See TURN SIGNAL SWITCH. Remove retaining screws.
Unplug harness connector. Remove windshield wiper switch. To install,
reverse removal procedure.
IGNITION SWITCH (ALL BUT CORRADO)
Removal (All But Corrado)
1) Remove steering wheel. See STEERING WHEEL & HORN PAD.
Remove lower cover from steering column. Remove turn signal and
windshield wiper switches. See TURN SIGNAL SWITCH and WINDSHIELD WIPER
SWITCH. Remove lock washer, spring and horn contact ring.
2) Remove bolt retaining steering column tube to steering
column housing. Disconnect wiring from ignition switch. Unlock
steering with ignition key. Remove steering column housing, ignition
lock and upper half of steering column switch cover. Remove retaining
screw and ignition switch.
Installation
To install ignition switch, reverse removal procedure.
Removal (Corrado)
1) Remove steering column and steering column switch. Insert
ignition key in ignition lock. Mark dimension "a" in Fig. 1. on line
with key (0.5" (12mm)).
2) Bore hole approximately 0.12" (3mm) in diameter through
steering lock housing until stop spring of lock cylinder is visible;
hole depth is approximately 0.12" (3mm). Compress stop spring with a
punch and pull out lock cylinder with key.