1993 VOLKSWAGEN CORRADO Repair Manual

VR65 ENGINE: AFFIX NEW VACUUM HOSE ROUTING LABEL
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 09:26PM
Osnabrueck, Germany
5. Evaluation of Emissions and Driveability of the Defect:
Not Applicable.
6. Available Emissions Data:
Not Applicable.
7. Anticipated Follow-Up Action:
VWoA will recall all affected vehicles and instruct dealers to
affix a new label in addition to performing safety recall work.
The details of the safety recall have been reported to the
NHTSA.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄATTACHMENT I
RECALL CAMPAIGN BULLETIN - SQ
Date: July 1993
SECURE ENGINE COMPARTMENT ELECTRICAL WIRING AND AFFIX
VACUUM HOSE ROUTING LABEL
REPLACEMENT PARTS REQUIRED
ÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄRepair Step
³ Quantity ³ Description ³ Part Number
ÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄ A
³ 1 (290 mm) ³ Protective Sleeve ³ N905 930.01

³ 1 ³ Beading ³ 535 853 879 A

³ 1 ³ Tie Wrap ³ N020 906.3

³ 3 ³ Tie Wrap ³ ZVW 601 100
B
³ 2 ³ Lock Nut ³ N902 920.01
C
³ ³ No parts required ³ D
³ 1 ³ Beading ³ 701 947 149A
E
³ 1 ³ Clamp ³ 535 253 139
F
³ 1 ³ ECM ³ 095 927 731BD
G
³ 1 ³ Label ³ 021 010 058G
ÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄ General Repair Information
REPAIR STEPS TO BE PERFORMED
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ VIN Range
³ Repair Steps
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄFrom 50_NK 000 001 through 50_PK 002 707
³ A, B, C, D, E and G
From 50_PK 000 708 through 50_PK 003 049
³ A, B, C, D, and E

VR65 ENGINE: AFFIX NEW VACUUM HOSE ROUTING LABEL
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 09:26PM
From 50_PK 003 050 through 50_PK 005 031 ³ A, B, C, and D
From 50_NK 004 148 through 50_NK 012 142
³ A, C, D, E, F and G

³ (automatic transmission

³ vehicles)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ REPAIR STEPS EXPLANATION:
Repair Step A - Secure Cooling Fan Wiring Harness
Repair Step B - Modify Shift Linkage Balance Weight Mounting
(Standard Transmission Only)
Repair Step C - Re-route Ignition Cables and Breather Hose
Repair Step D - Secure Engine Compartment Harness
Repair Step E - Secure Exhaust System
Repair Step F - Replace Transmission Control Module (Automatic
Transmission Only)
Repair Step G - Replace Vacuum Hose Routing Label
WORK PROCEDURE
A. Secure Cooling Fan Wiring Harness
- Open hood
- Connect power saver to protect radio code
- Remove battery
- Disconnect harness plug from fan motor
- Cut protective sleeve, part number N 905 930.01 into
individual lengths according to the indicated measurements
in Fig. 1.
- Pull open each protective sleeve longways and slide over
harness according to Fig. 1.Fig. 1: Protective Sleeve Measurements
- Place protective sleeves approx. 10mm from each branching off

VR65 ENGINE: AFFIX NEW VACUUM HOSE ROUTING LABEL
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 09:26PM
of the harness wires (see Fig. 2, arrows).
- Turn sleeves so that longitudinal cut does contact any engine
or body part.
- Use electrical textile tape, part number ZVW 601 100 and
secure protective sleeves by taping each end.Fig. 2: Placing Protective Sleeves on Harness Branches
- Install beading part number 535 853 879A to edge of fan cowl
(see Fig. 3, marked "1").
- Re-connect harness to fan motor
- Use tie wrap, part number N020 906.3 and secure harness to fan
motor (see Fig. 3, marked "2").
- Ensure that protective sleeve (see Fig. 3, marked "3") is
routed past fan motor housing edge, see arrow in Fig. 3.Fig. 3: Installing Beading and Proper Protective Sleeve Routing
- Push protective sleeve of harness into cowl bracket (see

VR65 ENGINE: AFFIX NEW VACUUM HOSE ROUTING LABEL
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 09:26PM
Fig. 4, marked "4") and secure with two (2) tie wraps,
part number N 020 902.2.
- Secure harness for temperature sensor (see Fig. 3, marked "A")
to battery ground cable (as shown in Fig. 4, marked "6") with
tie wrap, part number N 020 902.2.
- Push excess length harness downward.
- Carefully open re-usable tie wrap (see Fig. 4, marked "8")
- Route harness with protective sleeve (see Fig. 3, marked "7")
towards front above temperature sensor and re-secure with
re-usable tie wrap (see Fig. 4, marked "4").Fig. 4: Securing and Routing Harness
B. Modify Shaft Linkage Balance Weight Mounting
(Standard Transmission Vehicles Only)
- Remove air cooling hose for the front exhaust pipe (see
Fig. 5, marked "1") by loosening bolt (arrow), Pull hose
from air duct (see Fig. 5, marked "2")

VR65 ENGINE: AFFIX NEW VACUUM HOSE ROUTING LABEL
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 09:26PMFig. 5: Removing Air Cooling Hose
- Remove back-up light switch.
- Replace nut (see Fig. 6, marked "A") for the gear box switch
level (see Fig. 3, marked "1") with new self-locking nut,
part number N 902 920.01; torque to 25 Nm (18 ft.lbs.)Fig. 6: Replacing Nut with Self-Locking Nut
- Remove nut (see Fig. 7, marked "B") for the balance weight

VR65 ENGINE: AFFIX NEW VACUUM HOSE ROUTING LABEL
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 09:26PM
mounting and remove balance weight (see Fig. 7, marked "2").
- Re-torque stud (see Fig. 7, marked "C") to 25 Nm (18 ft.lbs.)
- Re-install balance weight (see Fig. 7, marked "2") and secure
with new self-locking nut, part number N 902 920.01; torque to
25 Nm (18 ft.lbs.)Fig. 7: Replacing Nut on Balance Wheel
C. Check/Re-Route Ignition Cable and Cylinder Head Breather Hose
- Check if ignition cable (see Fig. 8, marked "1") is clipped
into retainer, if not, correct.
NOTE: White cable marking must be in retainer.
- Check if the tightening screw (see Fig. 8, marked "3") of the
breather hose clamp does contact an ignition cable. If so,
rotate clamp to avoid contact.
- Check proper installation of breather hose (see Fig. 8,
arrow markings "4" and "5" must align; correct, if necessary).
- Ensure proper distance between breather hose and engine
components (see Fig. 9, arrows), correct if necessary by
slightly rotating breather hose.

VR65 ENGINE: AFFIX NEW VACUUM HOSE ROUTING LABEL
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 09:26PMFig. 8: Proper Breather Hose InstallationFig. 9: Ensuring Proper Distance Between Breather Hose and Engine
D. Secure Engine Compartment Harness at Left Side Frame Member

VR65 ENGINE: AFFIX NEW VACUUM HOSE ROUTING LABEL
Article Text (p. 9)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:26PM
- Open re-usable tie wrap (see Fig. 10, marked "2")
- Install beading, part number 701 947 149A over sheet metal
edge (see Fig. 10, marked "1")
- Route harness over beading, re-secure with reusable tie wrap.
- Re-install battery.
- Remove power saver.Fig. 10: Securing Engine Compartment Harness
E. Check Rear Muffler Clamp
- Lift vehicle
- Check, by twisting center muffler (see Fig. 11), if the clamp
connecting the catalyst and center muffler is tightly secured
or shows traces of exhaust leak.
- If loose or evidence of exhaust leak, replace clamp (see
Fig. 11, marked "1") with part number 535 253 139, torque to
60 Nm (44 ft. lbs.).
- Lower vehicle.