1993 VOLKSWAGEN CORRADO change time

A/C SYSTEM GENERAL DIAGNOSTIC PROCEDURES
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 08:48PM
* Restricted air inlet.
* Mode doors binding.
* Blower motor inoperative.
* Temperature above system capacity.
HEATING GENERAL TROUBLE SHOOTING
CONDITION & POSSIBLE CAUSE
Insufficient, Erratic, or No Heat
* Low coolant level.
* Incorrect thermostat.
* Restricted coolant flow through heater core.
* Heater hoses plugged.
* Misadjusted control cable.
* Sticking heater control valve.
* Vacuum hose leaking.
* Vacuum hose blocked.
* Vacuum motors inoperative.
* Blocked air inlet.
* Inoperative heater blower motor.
* Oil residue on heater core fins.
* Dirt on heater core fins.
Too Much Heat
* Improperly adjusted cables.
* Sticking heater control valve.
* No vacuum to heater control valve.
* Temperature door stuck open.
Airflow Changes During Acceleration
* Vacuum system leak.
* Bad check valve or reservoir.
Air From Defroster At All Times
* Vacuum system leak.
* Improperly adjusted control cables.
* Inoperative vacuum motor.
Blower Does Not Operate Correctly
* Blown fuse.
* Blower motor windings open.
* Resistors burned out.
* Motor ground connection loose.
* Wiring harness connections loose.
* Blower motor switch inoperative.
* Blower relay inoperative.
* Fan binding or foreign object in housing.
* Fan blades broken or bent.
END OF ARTICLE

E - THEORY/OPERATION
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 09:09PM
Fuel Injectors
See FUEL CONTROL under FUEL SYSTEM in this article.
Fuel Pump
See FUEL DELIVERY under FUEL SYSTEM in this article.
Idle Air Control/Stabilizer Valve
See IDLE SPEED under FUEL SYSTEM in this article.
Ignition Coil & Output Stage
See DISTRIBUTORLESS IGNITION SYSTEM (DIS) under IGNITION
SYSTEM in this article.
Malfunction Indicator (CHECK ENGINE) Light
See MALFUNCTION INDICATOR (CHECK ENGINE) LIGHT under SELF-
DIAGNOSTIC SYSTEM in this article.
FUEL SYSTEM
FUEL DELIVERY
Fuel Pump
A 2-stage fuel pump, located in fuel tank, is used (one motor
drives two separate pumps). The stage one vane-type pump draws fuel,
through a screen, from bottom of fuel tank and into an accumulator.
The vane-type pump acts as a transfer pump. The stage two gear-type
pump draws fuel from bottom of accumulator and out fuel lines.
Fuel Pressure Regulator
The diaphragm-type fuel pressure regulator is attached to
fuel return side of fuel rail. Fuel pressure is regulated depending on
intake manifold pressure. As intake manifold pressure changes, the
pressure regulator will increase or decrease fuel system pressure.
FUEL CONTROL
Fuel Injectors
Fuel injectors are supplied with battery (system) voltage
through power supply relay and are controlled (grounded) by the ECM.
Injectors are opened sequentially in cylinder firing order. Fuel
quantity is determined by injector on time (duty cycle).
IDLE SPEED
Idle Air Control/Stabilizer Valve
The idle air control/stabilizer valve is actuated by the ECM
thorough the valve's ground control circuit. When a defect in circuit
is recognized, both output stages are shut-off and the valve rotates
to a fixed potion. This permits engine to idle at a warm engine idle
speed.
IGNITION SYSTEM

ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
Article Text (p. 11)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:09PM
grinding machine.
Valve Lapping
During valve lapping of recent designed valves, be sure to
follow manufacturers recommendations. Surface hardening and materials
used with some valves do not permit lapping. Lapping process will
remove excessive amounts of the hardened surface.
Valve lapping is done to ensure adequate sealing between
valve face and seat. Use either a hand drill or lapping stick with
suction cup attached.
Moisten and attach suction cup to valve. Lubricate valve stem
and guide. Apply a thin coat of fine valve grinding compound between
valve and seat. Rotate lapping tool between the palms or with hand
drill.
Lift valve upward off the seat and change position often.
This is done to prevent grooving of valve seat. Lap valve until a
smooth polished seat is obtained. Thoroughly clean grinding compound
from components. Valve to valve seat concentricity should be checked.
See VALVE SEAT CONCENTRICITY.
CAUTION: Valve guides must be in good condition and free of carbon
deposits prior to valve seat grinding. Some engines contain
an induction hardened valve seat. Excessive material removal
will damage valve seats.
Valve Seat Grinding
Select coarse stone of correct size and angle for seat to be
ground. Ensure stone is true and has a smooth surface. Select correct
size pilot for valve guide dimension. Install pilot in valve guide.
Lightly lubricate pilot shaft. Install stone on pilot. Move stone off
and on the seat approximately 2 times per second during grinding
operation.
Select a fine stone to finish grinding operation. Grinding
stones with 30 and 60 degree angles are used to center and narrow the
valve seat as required. See Fig. 10.Fig. 10: Adjusting Valve Seat Width - Typical
This Graphic For General Information Only

ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
Article Text (p. 15)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:09PMFig. 13: Typical Hydraulic Valve Lifter Assemblies - Typical
This Graphic For General Information Only
On sticking lifters, disassemble and clean lifter. DO NOT mix
lifter components or positions. Parts are select-fitted and are not
interchangeable. Inspect all components for wear. Note amount of wear
in lifter body-to-camshaft contact area. Surface must have smooth and
convex contact face. If wear is apparent, carefully inspect cam lobe.
Inspect push rod contact area and lifter body for scoring
or signs of wear. If body is scored, inspect lifter bore for damage
and lack of lubrication. On roller type lifters, inspect roller for
flaking, pitting, loss of needle bearings and roughness during
rotation.
Measure lifter body O.D. in several areas. Measure lifter
bore I.D. of cylinder block. Some models offer oversized lifters.
Replace lifter if damaged.
If lifter check valve is not operating, obstructions may be
preventing it from closing or valve spring may be broken. Clean or
replace components as necessary.
Check plunger operation. Plunger should drop to bottom of the
body by its own weight when assembled dry. If plunger is not free,
soak lifter in solvent to dissolve deposits.
Lifter leak-down test can be performed on lifter. Lifter
must be filled with special test oil. New lifters contain special test
oil. Using lifter leak-down tester, perform leak-down test following
manufacturer's instructions. If leak-down time is not within
specifications, replace lifter assembly.
Lifters should be soaked in clean engine oil several hours
prior to installation. Coat lifter base, roller (if equipped) and
lifter body with ample amount of Molykote or camshaft lubricant. See

FUSES & CIRCUIT BREAKERS
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 09:11PM
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.
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.
BATTERY WARNING
WARNING: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure. See COMPUTER
RELEARN PROCEDURES article in GENERAL INFORMATION section.
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning
that brake pads need replacement.
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.
SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)
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

HOW TO USE SYSTEM WIRING DIAGRAMS
Article Text
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:11PM
ARTICLE BEGINNING
GENERAL INFORMATION
Using Wiring Diagrams
All Models
INTRODUCTION
Mitchell obtains wiring diagrams and technical service
bulletins, containing wiring diagram changes from the domestic and
import manufacturers. These are checked for accuracy and are all
redrawn into a consistent format for easy use.
In the past, when cars were simpler, diagrams were simpler.
All components were connected by wires and diagrams seldom exceeded 4
pages in length. Today, some wiring diagrams require more than 16
pages. It would be impractical to expect a service technician to trace
a wire from page 1 across every page to page 16.
Removing some of the wiring maze reduces eyestrain and time
wasted searching across several pages. Today the majority of Mitchell
diagrams follow a much improved format, which permits space for
internal switch details.
Wiring diagrams are drawn in a "top-down" format. The
diagrams are drawn with the power source at the top of the diagram and
the ground point at the bottom of the diagram. Components locations
are identified on the wiring diagrams. Any wires that don't connect
directly to a component are identified on the diagram to indicate
where they go.
COLOR ABBREVIATIONS
COLOR ABBREVIATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄColor Normal Optional
Black ................ BLK .......................... BK
Blue ................. BLU .......................... BU
Brown ................ BRN .......................... BN
Clear ................ CLR .......................... CR
Dark Blue .......... DK BLU ...................... DK BU
Dark Green ......... DK GRN ...................... DK GN
Green ................ GRN .......................... GN
Gray ................. GRY .......................... GY
Light Blue ......... LT BLU ...................... LT BU
Light Green ........ LT GRN ...................... LT GN
Orange ............... ORG .......................... OG
Pink ................. PNK .......................... PK
Purple ............... PPL .......................... PL
Red .................. RED .......................... RD
Tan .................. TAN .......................... TN

MAINTENANCE INFORMATION
Article Text (p. 11)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:14PM
Application Quantity (1)
A/C System R-12 Refrigerant
1990-92 (up to 7/92) ............................. 37-40 Ozs.
A/C System R-134a Refrigerant (2)
1993-94 (from 7/92) ........................... 28.2-31.8 Ozs.
Cooling System
4-Cyl. ...................................... 6.8 Qts. (6.5L)
V6 .......................................... 9.1 Qts. (8.6L)
Engine Oil (3)
4-Cyl. ...................................... 4.3 Qts. (4.0L)
V6 .......................................... 6.3 Qts. (6.0L)
Fuel Tank
4-Cyl. ..................................... 14.5 Gals. (55L)
V6 ......................................... 18.5 Gals. (55L)
Automatic Transmission
Fluid Change ................................ 3.2 Qts. (3.0L)
Overhaul .................................... 5.9 Qts. (5.6L)
Manual Transmission ........................... 2.1 Qts. (2.0L)
Final Drive
Differential (A/T) (4) ....................... 0.8 Qt. (.75L)
(1) - Capacities are recommended or calculated levels. Always use
dipstick (if available) to measure level.
(2) - Use of R-12 in a R134a system will result in SEVERE DAMAGE.
(3) - Includes oil filter change.
(4) - Lifetime fill.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ WHEEL & TIRE SPECIFICATIONS
Wheel and tire sizes vary according to vehicle and equipment
and can be found on tire information label on each vehicle. Wheel and
tire specifications and tire inflation pressures are listed on a label
found inside fuel tank flap.
NOTE: Snow chains must be used on drive wheels, in pairs only.
WHEEL TIGHTENING
Tighten all wheel lugs to 80 ft. lbs. (110 N.m).
BATTERY SPECIFICATIONS
CAUTION: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure. See COMPUTER
RELEARN PROCEDURES article in the GENERAL INFORMATION
section.
All models use BCI group 41 batteries with cold crank rating

MAINTENANCE REMINDER LIGHT RESET PROCEDURES
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 09:20PM
flash for approximately 3 seconds in odometer display window as
ignition is turned on. When servicing becomes due (every 7500 miles),
appropriate service code will flash for approximately 60 seconds. The
four service codes available for display are as follows:
* IN 00 (No Service Necessary)
* OEL (Oil Change Service) Every 7500 Miles
* IN 01 (Inspection Service) Every 15,000 Miles
* IN 02 (Additional Servicing Work) Every 30,000 Miles
2) After performing required maintenance, each effected
service code displayed must be reset individually. For example, at 15,
000 miles service codes OEL and IN 01 will both need to be reset.
3) To reset service codes, turn ignition on. Press and hold
odometer reset button located below speedometer. While holding button,
press clock reset button (lower button for digital clock) located to
left of fuel gauge. Release buttons. Programming mode is now
activated. Service code OEL1.S (distance counter) should be displayed.
4) Press clock reset button once more. 7500 miles should now
be indicated on display. Desired mileage for reset may be attained by
pressing clock reset button. Mileage displayed will decrease in
increments of 500 miles each time button is pressed. This feature
should only be used to calibrate mileage when instrument cluster is
replaced. When desired mileage is displayed, press odometer reset
button.
5) Service code OEL2.S (time counter) should be displayed.
Press clock reset button. 6 (months) will be indicated on display.
Time counter for next oil change may be set by pressing clock reset
button if instrument cluster was replaced. When desired time is
displayed, press odometer reset button.
6) Service code IN 01.S (time counter) should be displayed.
Press clock reset button. 12 (months) will be indicated on display.
Time counter for next maintenance interval may be set by pressing
clock reset button if instrument cluster was replaced. When desired
time is displayed, press odometer reset button.
7) Service code IN 02.S (distance counter) should be
displayed. Press clock reset button. 30,000 (miles) will be indicated
on display. Desired mileage for reset may be attained by pressing
clock reset button. Mileage displayed will decrease in increments of
500 miles each time button is pressed. This feature should only be
used to calibrate mileage when instrument cluster is replaced. When
desired mileage is displayed, turn ignition off. Programming is now
stored in memory.
END OF ARTICLE