1990 VOLKSWAGEN CORRADO alternator

1990 Volkswagen Corrado All Categories All Sections
Title List for Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:54PM* A/C-HEATER SYSTEM UNIFORM INSPECTION GUIDELINES ** ANTI-LOCK BRAKES UNIFORM INSPECTION GUIDELINE ** AUTO TRANS DIAGNOSIS MENU - VOLKSWAGEN* BRAKE SYSTEM UNIFORM INSPECTION GUIDELINES ** ELECTRICAL SYSTEM UNIFORM INSPECTION GUIDELINES ** ENGINE SYSTEMS UNIFORM INSPECTION GUIDELINES ** EXHAUST SYSTEM UNIFORM INSPECTION GUIDELINES ** STEERING UNIFORM INSPECTION GUIDELINES ** SUSPENSION UNIFORM INSPECTION GUIDELINES ** SYMPTOM CHECK LIST *1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVEA - ENGINE/VIN IDA/C COMPRESSOR OIL CHECKINGA/C COMPRESSOR SERVICINGA/C SYSTEM GENERAL DIAGNOSTIC PROCEDURESA/C SYSTEM PRECAUTIONSA/C-HEATER SYSTEM - MANUALAA - USING THIS SECTION (GENERAL HELP INFORMATION)ABBREVIATIONSABBREVIATIONSALTERNATOR & REGULATOR - BOSCHANTI-LOCK BRAKE SAFETY PRECAUTIONSANTI-LOCK BRAKE SYSTEMB - EMISSION APPLICATIONC - SPECIFICATIONSCOMPUTER RELEARN PROCEDURESD - ADJUSTMENTSDRIVE AXLE - GEAR TOOTH CONTACT PATTERNSE - THEORY/OPERATION - DIGIFANTELECTRICAL COMPONENT LOCATORELECTROSTATIC DISCHARGE WARNING - BASIC INFORMATIONEMISSION CONTROL VISUAL INSPECTION PROCEDURESENGINE OVERHAUL PROCEDURES - GENERAL INFORMATIONF - BASIC TESTINGFUEL HOSE MAY SHRINK & LEAK CAUSING FIRE: NEW CLAMPFUEL LEAKAGE COULD CAUSE FIRE:NEW FUEL HOSE & CLAMPSFUSES & CIRCUIT BREAKERSG - TESTS W/CODESGEAR TOOTH CONTACT PATTERNSGENERAL COOLING SYSTEM SERVICINGH - TESTS W/O CODESHEATER SYSTEMI - SYSTEM/COMPONENT TESTSINSTRUMENT PANELINTERFERENCE VERIFICATION CHECK FOR OHC ENGINE

* ELECTRICAL SYSTEM UNIFORM INSPECTION GUIDELINES *
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 09:29PM
³ ³ indicates low fluid level

³ ³ require replacement.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄSwollen casing
³ Further inspection ³ No service suggested or

³ required. ³ required unless the
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ battery fails load test
Electrolyte
³ ³ or fails to accept or
discoloration/
³ ³ hold a charge -
contamination
³ ³ replacement required.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄWet/dirty top
³ Clean battery using ³ Check fluid level and

³ BCI procedures. ³ adjust to manufacturer's

³ Further inspection ³ specification. Check

³ required. ³ charging system for

³ ³ proper operation.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄFrozen battery
³ Further inspection ³ Do not attempt to charge

³ required. ³ a frozen battery. Allow

³ ³ battery to warm and then

³ ³ recharge and test to

³ ³ manufacturer's

³ ³ specifications.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ BATTERY TRAY/HOLD DOWN HARDWARE
BATTERY TRAY/HOLD DOWN HARDWARE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄCondition
³ Procedure ³ Note
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄMissing
³ Require replacement. ³
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄDamaged/corroded
³ Suggest repair or ³ If battery tray/hold down

³ replacement. ³ hardware no longer

³ ³ performs intended purpose

³ ³ require repair or

³ ³ replacement.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ CHARGING SYSTEM
NOTE: Inoperative means output does not meet OE specs for the
intended vehicle. If components have been added that increase
vehicle electrical load requirement (e.g., sound systems, air
conditioning, alarm systems, etc.) charging system output
must meet the increased demand.
ALTERNATOR/GENERATOR
ALTERNATOR/GENERATOR
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄCondition
³ Procedure

1.8L 4-CYL 8-VALVE & 1.8L 4-CYL 16-VALVE
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 09:40PM
NOTE: Match mark engine mounts to ensure original alignment is
achieved after installation. On vehicles with A/C and power
steering, remove components with hoses attached and secure
out of way.
ENGINE R & I (EXCEPT FOX)
REMOVAL (EXCEPT FOX)
1) Disconnect and remove battery. Open fuel tank fill cap and
radiator cap. Remove intake air duct. On 16-valve engines, remove
intake manifold assembly. On vehicles with A/C, remove trim panel and
lower apron. Remove condenser from crossmember and radiator. Remove
all duct work. Mark and disconnect A/C and cooling fan electrical
connectors. Remove accessory belts.
2) On Golf, GTI and Jetta models, leave A/C hoses attached
and remove A/C compressor. Pivot A/C condenser and compressor to side
of vehicle and secure.
3) On Cabriolet and Scirocco models, remove alternator and
timing belt cover. Remove 3 A/C bracket Allen head bolts behind timing
belt cover. Remove A/C bracket support brace. Remove A/C compressor
bracket bolts. Leave hoses attached and secure A/C compressor with
bracket out of way.
4) On all models, open heater controls. Remove cooling hose
from thermostat housing flange and drain coolant. Remove flange. Mark
and remove all cooling system hoses (as necessary).
5) On Golf, GTI and Jetta models, remove grille from radiator
support. Disconnect electrical connectors at radiator support. Remove
radiator-to-support bolts. Remove radiator support using care not
damage headlights. Remove radiator, fan and shroud assembly.
6) On all models, remove axle shafts from transaxle. See FWD
AXLE SHAFTS article in the DRIVE AXLES section. Mark and disconnect
shift linkage and speedometer cable. Mark and remove electrical
connectors and vacuum hoses (as necessary). Disconnect throttle,
cruise and kickdown cables (if equipped). Leave fuel lines connected
and remove cold start injector and warm-up regulator.
7) Remove fuel injectors and install protective caps and
plugs. Remove rear engine mount. Remove complete transaxle mount. On
Cabriolet models, remove right front tire assembly. Remove right and
left engine mount through bolts.
8) On all models, install engine sling on engine lift hooks.
Carefully raise engine and transaxle out of vehicle. Separate
transaxle from engine (if necessary).
INSTALLATION
1) To install, reverse removal procedure. Engine alignment
adjustment is necessary whenever engine is removed or mounts are
loosened. To adjust, loosen through bolt on engine mount "A". Loosen
transmission transaxle mount "B" bolts. Loosen front engine mount and
bracket. See Fig. 2.
2) Lightly rock engine and transaxle to allow position to

ABBREVIATIONS
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:42PM
ARTICLE BEGINNING
GENERAL INFORMATION
COMMONLY USED ABBREVIATION
"A" ABBREVIATION TABLE
"A" ABBREVIATION TABLEÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿
³ABBREVIATION
³DEFINITION ³
ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´
³A
³Amperes ³
³A/C
³Air Conditioning ³
³A/T
³Automatic Transmission/Transaxle ³
³AAP
³Auxiliary Accelerator Pump ³
³AB
³Air Bleed ³
³ABCV
³Air Bleed Control Valve ³
³ABDC
³After Bottom Dead Center ³
³ABRS
³Air Bag Restraint System ³
³ABS
³Anti-Lock Brake System ³
³AC
³Alternating Current ³
³ACC
³A/C Clutch Compressor ³
³ACCS
³A/C Cycling Switch ³
³ACCUM
³Accumulator ³
³ACCY
³Accessory ³
³ACT
³Air Charge Temperature Sensor ³
³ACV
³Thermactor Air Control Valve ³
³ADJ
³Adjust or Adjustable ³
³ADV
³Advance ³
³AFS
³Airflow Sensor ³
³AI
³Air Injection ³
³AIR or A.I.R.
³Air Injection Reactor ³
³AIS
³Air Injection System ³
³ALCL
³Assembly Line Communications Link ³
³ALDL
³Assembly Line Diagnostic Link ³
³ARC
³Automatic Ride Control ³
³ASCS
³Air Suction Control Solenoid ³
³ASD
³Auto Shutdown ³
³ASDM
³Air Bag System Diagnostic Module ³
³ASV
³Air Suction Valve ³
³ATC
³Automatic Temperature Control ³
³ATDC
³After Top Dead Center ³
³ATF
³Automatic Transmission Fluid ³
³ATS
³Air Temperature Sensor ³
³AXOD
³Automatic Transaxle Overdrive ³
³Abs.
³Absolute ³
³Accy.
³Accessory ³
³Alt.
³Alternator or Altitude ³
³Amp.
³Ampere ³
³Assy.
³Assembly ³

ABBREVIATIONS
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:42PM
ARTICLE BEGINNING
GENERAL INFORMATION
COMMONLY USED ABBREVIATION
"A" ABBREVIATION TABLE
"A" ABBREVIATION TABLEÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿
³ABBREVIATION
³DEFINITION ³
ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´
³A
³Amperes ³
³A/C
³Air Conditioning ³
³A/T
³Automatic Transmission/Transaxle ³
³AAP
³Auxiliary Accelerator Pump ³
³AB
³Air Bleed ³
³ABCV
³Air Bleed Control Valve ³
³ABDC
³After Bottom Dead Center ³
³ABRS
³Air Bag Restraint System ³
³ABS
³Anti-Lock Brake System ³
³AC
³Alternating Current ³
³ACC
³A/C Clutch Compressor ³
³ACCS
³A/C Cycling Switch ³
³ACCUM
³Accumulator ³
³ACCY
³Accessory ³
³ACT
³Air Charge Temperature Sensor ³
³ACV
³Thermactor Air Control Valve ³
³ADJ
³Adjust or Adjustable ³
³ADV
³Advance ³
³AFS
³Airflow Sensor ³
³AI
³Air Injection ³
³AIR or A.I.R.
³Air Injection Reactor ³
³AIS
³Air Injection System ³
³ALCL
³Assembly Line Communications Link ³
³ALDL
³Assembly Line Diagnostic Link ³
³ARC
³Automatic Ride Control ³
³ASCD
³Automatic Speed Control Device ³
³ASCS
³Air Suction Control Solenoid ³
³ASD
³Auto Shutdown ³
³ASDM
³Air Bag System Diagnostic Module ³
³ASV
³Air Suction Valve ³
³ATC
³Automatic Temperature Control ³
³ATDC
³After Top Dead Center ³
³ATF
³Automatic Transmission Fluid ³
³ATS
³Air Temperature Sensor ³
³AXOD
³Automatic Transaxle Overdrive ³
³Abs.
³Absolute ³
³Accy.
³Accessory ³
³Alt.
³Alternator or Altitude ³
³Amp.
³Ampere ³

ALTERNATOR & REGULATOR - BOSCH
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:42PM
ARTICLE BEGINNING
1989-92 ELECTRICAL
Alternators & Regulators - Bosch
Cabriolet, Fox, Golf, GTI, Jetta, Jetta GLI, Vanagon
1991 Corrado, Passat & Golf GL
NOTE: Some Golf, GTI, Jetta and Jetta GLI models may use a
Motorola alternator. Please refer to ALTERNATORS - SEV
MOTOROLA article. Vanagon models only use Bosch 90-amp
alternators.
DESCRIPTION
Bosch alternators are conventional 3-phase, self-rectifying
type alternators. Bosch 65 through 75-amp alternators use 3 positive
and 3 negative diodes connected to stator windings to rectify current.
Bosch 90-amp alternators use 14 diodes.
All alternators use 3 exciter diodes connected to stator
windings. These diodes turn off the alternator indicator light and
supply power to the voltage regulator while the engine is running.
Bosch regulators are transistorized and integral with alternator.
BELT TENSION ADJUSTMENT
BELT TENSION SPECIFICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication (1) Deflection In. (mm)
New Belt ................................... 5/64 (2)
Used Belt ................................. 13/64 (5)
(1) - Deflection is with 22 lbs. (10 kg) pressure
applied midway on longest belt run.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ TESTING (ON-VEHICLE)
WIRING CONTINUITY TEST
1) Connect a voltmeter between alternator "B+" terminal and
ground. Voltmeter should indicate battery voltage. If not, check
wiring between alternator and battery.
2) Turn ignition on and ensure alternator indicator light
comes on. If light does not come on, check wiring between alternator
and warning light, including indicator bulb.
OUTPUT TEST
1) Ensure connections at battery, alternator, and starter

ALTERNATOR & REGULATOR - 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 09:42PM
(most vehicles) are clean and tight. Ensure alternator, engine and
body are properly grounded. Ensure alternator drive belt is tight and
in good condition.
2) Connect ammeter following manufacturer's instructions.
Connect voltmeter leads to battery terminals. Adjust carbon pile on
tester until voltmeter reads 13.5 volts. Alternator output should be
28-35 amps.
3) Repeat process at 1000 RPM. Alternator output should be
75-85 amps. Repeat test at 2000 RPM. Alternator output should be 89
amps. If alternator output is low, remove alternator for testing and
repairs.
4) Start engine and run at 3000 RPM. Adjust carbon pile on
tester to obtain maximum alternator output. Do not allow voltage to go
below 12.6 volts.
5) Alternator output should equal alternator rated output,
minus 16-20 amps. If reading is 16-20 amps below alternator rating,
replace regulator and retest. If output is still low, repair or
replace alternator.
REGULATOR CONTROL VOLTAGE TEST
1) Connect ammeter following manufacturer's instructions.
Connect voltmeter leads to battery terminals. Start engine and run at
3000 RPM.
2) Run engine until voltage stops rising. Voltage should be
13.5-14.5 volts. If reading is incorrect, remove regulator and ensure
brushes are longer than 7/32" (6 mm). Replace if necessary.
3) If brushes are okay and regulator fails to keep voltage
within specified limits, replace regulator and retest. If voltage is
still incorrect, repair or replace alternator.
BENCH TESTING
DIODE ASSEMBLY
1) Place ohmmeter on x 100 scale. Connect ohmmeter leads
across "B+" terminal and 3 stator terminals one at a time. Reverse
leads. Ohmmeter should indicate continuity in one direction only.
2) Connect ohmmeter leads across negative plate and 3 stator
terminals one at a time. See Fig. 1. Reverse leads. Ohmmeter should
indicate continuity in one direction only.
3) Connect ohmmeter leads across "D+" terminal and 3 stator
terminals one at a time. Reverse leads. Ohmmeter should indicate
continuity in one direction only. Replace diode assembly if defective.

ALTERNATOR & REGULATOR - 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 09:42PMFig. 1: Bosch Diode Assembly Test
Courtesy of Volkswagen United States, Inc.
STATOR
1) Place ohmmeter on lowest scale. Connect ohmmeter across
stator leads. Resistance between leads should be approximately .14-.15
ohms for 55-amp alternator and .09-.10 ohms for 65 through 90-amp
alternators. If resistance is incorrect, stator has open or shorted
windings and must be replaced.
2) Place ohmmeter on X 1000 scale. Connect ohmmeter between
stator core and stator lead. No continuity should exist. If continuity
exists, stator is grounded and must be replaced.
ROTOR
1) Place ohmmeter on lowest scale. Connect ohmmeter across
slip rings. Resistance should be 2.8-3.1 ohms for 65 through 90-amp
alternators.
2) If resistance is too low, rotor has short circuit and must
be replaced. If resistance is infinity (no continuity), rotor has open
circuit and must be replaced.
3) Place ohmmeter on x 1000 scale. Connect ohmmeter between
either slip ring and rotor core. No continuity should exist. If
continuity exists, rotor is grounded and must be replaced.
4) Clean slip rings using fine sandpaper. Rings which are
worn or pitted should be turned on lathe. Minimum ring diameter is 1