1990 VOLKSWAGEN CORRADO Repair Manual

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

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

TRANSMISSION SERVICING - M/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 09:52PM
GEARSHIFT LINKAGE ADJUSTMENTS
CABRIOLET
1) Pull boot from housing. Loosen shift rod clamp bolt so
lever moves freely on shift rod. Adjust shift finger in center of
lock-out plate so that there is an equal distance on both sides of
shift finger. See Fig. 1.Fig. 1: Adjusting Shift Finger (Cabriolet)
Courtesy of Volkswagen United States, Inc.
2) Adjust shift rod end so distance "A" is 9/16" (14 mm). See
Fig. 2. Tighten shift rod clamp to 14 ft. lbs (19 N.m). If shift
linkage is spongy or jams after adjustment, change distance "A" to
1/2" (13 mm). If shift linkage will not stay in adjustment, install
new clamp bolt and lock nut.

TRANSMISSION SERVICING - M/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 09:52PMFig. 2: Adjusting Shift Rod End (Cabriolet)
Courtesy of Volkswagen United States, Inc.
CORRADO & PASSAT
1) Place gearshift lever in Neutral position. Remove knob and
boot. Loosen bolt "A" and nut "B" sufficiently so that operating
cables move freely in centering holes. See Fig. 3. Install Shift
Linkage Gauge (3193). Loosen bolt "C". See Fig. 4.
2) Pivot locating pin under bearing plate. Tighten nut "D".
Place gearshift lever into left detent of slide. Move gearshift lever
and slide together to left stop. Tighten slide with bolt "D". Move
gearshift lever to right detent. Tighten bolt "E". Move gearshift
lever to right detent. Tighten bolt "C".

TRANSMISSION SERVICING - M/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 09:52PMFig. 3: Identifying Centering HolesFig. 4: Installing Shift Linkage Gauge
FOX
1) Shift transaxle into 1st gear. Push gearshift lever to
left stop. Release lever. If lever does not spring back .2-.4" (5-10
mm) to right, move gearshift lever housing very slightly in elongated
holes. If adjustment does not correct hard shifting, go to step 2).
2) Place gearshift lever in 1st gear position. Remove boot
and gearshift lever knob. Loosen clamp nut. Ensure shift finger slides
freely on shifter rod. Move gearshift lever to left, as far as it will
go. Release lever. Lever should spring back .2-.4" (5-10 mm). See
Fig. 5.

TRANSMISSION SERVICING - M/T
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 09:52PMFig. 5: Locating Shift Rod Clamp Nut
Courtesy of Volkswagen United States, Inc.
3) If lever does not spring back, move housing slightly
sideways. If further adjustment is required, go to step 4).
4) Place gearshift lever in Neutral position. Place lever
bearing housing in center of elongated hole. Loosen shift rod clamp
nut. See Fig. 5. Ensure shift finger slides freely on shift rod.
Remove gearshift lever knob and shift boot.
5) Align centering holes of gearshift lever housing and
gearshift lever bearing housing. Tighten bolts. Install Gearshift
Aligner (3057) with locating pin in front centering hole of vehicle.
See Fig. 6.Fig. 6: Installing Gearshift Aligner (Fox)
Courtesy of Volkswagen United States, Inc.
6) Place gearshift lever into left cutout of slide. Secure in
position by tightening lower knob. Move slide together with gearshift
lever to left side stop. Tighten upper knob.
7) Place gearshift lever into right cutout of slide (shift
position for 3rd/4th gears). Ensure transmission is in Neutral. Align

TRANSMISSION SERVICING - M/T
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 09:52PM
shift rod and shift finger. Tighten clamp nut. Remove Aligner. Place
gearshift lever into 1st gear position. Press gearshift lever to left
side stop. When gearshift lever is released, it should spring back
approximately .2-.4" (5-10 mm).
GOLF, GTI & JETTA
1) Place shift lever in Neutral position. Ensure transaxle is
also in Neutral. Loosen lower shifter rod clamp. See Fig. 7. Selector
lever must move freely on shifter rod.Fig. 7: Loosening Shift Rod Clamp (Golf, GTI, & Jetta)
Courtesy of Volkswagen United States, Inc.
2) Remove gearshift knob and boot. Position Adjustment Gauge
(3104) over shift rod. See Fig. 8. With transaxle in Neutral, align
shift rod with selector lever. Tighten shifter rod clamp to 19 ft.
lbs. (26 N.m).Fig. 8: Locating Adjustment Gauge
Courtesy of Volkswagen United States, Inc.
3) Move gearshift lever through all gear positions. Gears
must engage smoothly and without jamming. Reinstall gearshift knob and
boot.

TRANSMISSION SERVICING - M/T
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 09:52PM
VANAGON (4-SPEED)
1) Place gearshift lever in Neutral position. Align round
centering holes of upper gearshift lever housing plate with holes in
lower lever bearing plate.
2) Loosen nut on clamp that connects front and rear shift
rods. Ensure joints of shift rods slide freely. Remove spare tire. Set
shift lever on transaxle in vertical Neutral position.
3) At gearshift lever end of front shift rod, ensure stop
finger of front shift rod is in center of shift mechanism housing.
4) Adjust front shift rod end so there is 29/32" (23 mm)
clearance between front shift rod end and stop plate. Tighten shift
rod clamp.
5) Check for proper operation. Ensure shift lever does not
rub against heater pipe insulation.
VANAGON (5-SPEED SYNCRO)
1) Place gearshift lever in Neutral position. Align round
centering holes of upper gearshift lever housing plate with holes in
lower lever bearing plate.
2) Loosen nut on clamp that connects front and rear shift
rods. Ensure joints of shift rods slide freely. Remove skid plate.
Place shift lever on transaxle in vertical Neutral position.
3) Measure distance between reverse gear lock and stop shift
rod. Clearance should be 29/32" (23 mm). Tighten clamp in this
position. Ensure all gears engage without jamming. Check reverse
lockout operation. With transmission in 1st gear, measure distance
between gear shift lever and heater covering. Clearance should be
19/32" (15 mm).
END OF ARTICLE