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Volkswagn CORRADO 1990-1994 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Volkswagen Model: Corrado Model Years Covered: 1990, 1991, 1992, 1993, 1994 Trim Levels Covered: G60, VR6, SLC Codes Platform Code: VW A2 (Typ 35i) 👋 Introduction Market Position Positioning: The Volkswagen Corrado was a niche sports coupe, competing against cars like the Porsche 944, Toyota MR2, and Honda CRX in its initial years. It was positioned as a stylish, front-wheel-drive performance car with European flair. Competitive Analysis Rivals: Porsche 944, Toyota MR2, Honda CRX, Ford Probe, Mitsubishi Eclipse. Key Features Design: Distinctive wedge shape, active rear spoiler, large glass area, unique 'hook' design elements. Drivetrain: Front-engine, front-wheel-drive layout, known for its handling characteristics. Special Variants: G60 variant featuring the G-Lader supercharger, VR6 variant offering a potent 2.8L V6 engine. Value Proposition Manual Benefit: Enables cost savings by empowering owners to perform DIY repairs and maintenance, mirroring dealer-level service information. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service Repair Scope: Comprehensive mechanical and electrical repair, maintenance, and diagnostics. Page Count Page Count: More than 1000 pages Manual Type Type: Electronic Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: General Engine, Fuel System, Supercharger (G60), Digifant Engine Management (1.8L), Motronic Engine Management (VR6 2.8L), Exhaust System Drivetrain: Clutch, Transmission (Manual & Automatic, specific types may vary by market/year) Chassis: Suspension (Front & Rear), Brakes (Hydraulic System, ABS components if applicable), Steering System Body: Body Construction, Exterior Panels, Interior Trim, Doors, Windows, Sunroof (G-Lader specific features might be detailed) Electrical: General Electrical System, Wiring Diagrams, On-Board Diagnostics (OBD), Lighting, Instruments, HVAC (Heater, Air Conditioner) Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication. Diagnostics: Troubleshooting common issues, fault code interpretation, diagnostic procedures for various systems. Repair: Detailed step-by-step repair procedures for all major mechanical and electrical components, including engine, transmission, brakes, suspension, steering, and HVAC. Overhaul: Engine rebuild, transmission overhaul, brake caliper rebuild, suspension component replacement. Adjustment: Valve adjustments, clutch adjustment, steering alignment checks. Technical Depth Depth: Comprehensive: Covers everything from routine maintenance and basic repairs to complex diagnostics and complete overhauls. Suitable for both DIY enthusiasts and professional technicians. 📊 Manual Specifications File Format File Type: PDF Compatibility: All Windows versions, All Mac versions Software Requirements: Adobe Acrobat Reader (free download available), WinZip or WinRAR (free download available for extraction) Print Quality Quality: High Definition diagrams, Readable by any Devices with PDF Reader Printability: Ready to Print Binding Type Binding: Digital (PDF) - No physical binding Paper Type Paper: N/A (Digital Format) Features Navigation: Bookmarks for every chapter, Well-structured contents Installation: No need to install any extra software beyond PDF reader and extraction tools. ⚙️ Engine Specifications Primary Engine Engine 1: 1.8L G-Lader Supercharged (G60) Engine 1 Code: PG (G60) Engine 1 Displacement: 1781 cc (1.8 Liters) Engine 1 Power: 158 hp @ 5800 rpm (approx.) Engine 1 Torque: 166 lb-ft @ 4000 rpm (approx.) Engine 1 Fuel System: Digifant Electronic Fuel Injection with G-Lader supercharger Engine 1 Notable Features: G-Lader (scroll-type supercharger), intercooled induction. Secondary Engine Engine 2: 2.8L VR6 (VR6, SLC) Engine 2 Code: AAA (VR6) Engine 2 Displacement: 2791 cc (2.8 Liters) Engine 2 Power: 178 hp @ 5800 rpm (approx.) Engine 2 Torque: 180 lb-ft @ 4200 rpm (approx.) Engine 2 Fuel System: Bosch Motronic Electronic Fuel Injection Engine 2 Notable Features: Narrow-angle V6 configuration, smooth power delivery. 🔧 Transmission Standard Transmission Standard G60: 5-speed Manual (e.g., 02A gearbox) Transmission Standard Vr6: 5-speed Manual (e.g., 02A gearbox) Optional Transmission Optional G60: 4-speed Automatic (less common) Transmission Optional Vr6: 4-speed Automatic (e.g., 096/01M gearbox) Features Clutch Type: Hydraulically actuated, single dry plate Differential: Optional Syncro limited-slip differential (LSD) available on some models/markets, particularly early G60. 📐 Dimensions Exterior Length: Approx. 4205 mm (165.5 in) Width: Approx. 1690 mm (66.5 in) Height: Approx. 1315 mm (51.8 in) Wheelbase: Approx. 2470 mm (97.2 in) Weights Curb Weight G60: Approx. 1250 kg (2756 lbs) Curb Weight Vr6: Approx. 1360 kg (2998 lbs) Cargo Trunk Volume: Approx. 0.237 m³ (8.4 cu ft), expandable with rear seats folded. 🛡️ Safety Features Ratings NHTSA Front Impact: Not specifically rated for the early 1990s models under modern testing standards, but generally considered to have good structural integrity for its era. Active Features ABS: Anti-lock Braking System (ABS) typically standard on VR6 models, optional or not available on some earlier/base G60 models. Traction Control: Traction control (ASR) was an option on later VR6 models. Passive Features Airbags: Driver's side airbag standard on most models by the mid-90s; passenger airbag typically optional or unavailable in earlier years. Seatbelts: Three-point inertia-reel seatbelts with pretensioners (front). Rollover Protection: Reinforced A-pillars and B-pillars designed for structural rigidity. 💡 Technology Features Infotainment Audio System: Factory fitted radios with cassette players were common. Higher trims may have CD players or upgraded speaker systems. Aftermarket upgrades are prevalent. Driver Assistance Cruise...
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Volkswagn CORRADO 1990-1994 Workshop Service Repair ManualVolkswagn CORRADO 1990-1994 Workshop Service Repair ManualVolkswagn CORRADO 1990-1994 Workshop Service Repair ManualVolkswagn CORRADO 1990-1994 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Volkswagen
Model:
Corrado
Model Years Covered:
1990, 1991, 1992, 1993, 1994
Trim Levels Covered:
G60, VR6, SLC
Codes
Platform Code:
VW A2 (Typ 35i)
👋 Introduction
Market Position
Positioning:
The Volkswagen Corrado was a niche sports coupe, competing against cars like the Porsche 944, Toyota MR2, and Honda CRX in its initial years. It was positioned as a stylish, front-wheel-drive performance car with European flair.
Competitive Analysis
Rivals:
Porsche 944, Toyota MR2, Honda CRX, Ford Probe, Mitsubishi Eclipse.
Key Features
Design:
Distinctive wedge shape, active rear spoiler, large glass area, unique 'hook' design elements.
Drivetrain:
Front-engine, front-wheel-drive layout, known for its handling characteristics.
Special Variants:
G60 variant featuring the G-Lader supercharger, VR6 variant offering a potent 2.8L V6 engine.
Value Proposition
Manual Benefit:
Enables cost savings by empowering owners to perform DIY repairs and maintenance, mirroring dealer-level service information.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service Repair
Scope:
Comprehensive mechanical and electrical repair, maintenance, and diagnostics.
Page Count
Page Count:
More than 1000 pages
Manual Type
Type:
Electronic Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
General Engine, Fuel System, Supercharger (G60), Digifant Engine Management (1.8L), Motronic Engine Management (VR6 2.8L), Exhaust System
Drivetrain:
Clutch, Transmission (Manual & Automatic, specific types may vary by market/year)
Chassis:
Suspension (Front & Rear), Brakes (Hydraulic System, ABS components if applicable), Steering System
Body:
Body Construction, Exterior Panels, Interior Trim, Doors, Windows, Sunroof (G-Lader specific features might be detailed)
Electrical:
General Electrical System, Wiring Diagrams, On-Board Diagnostics (OBD), Lighting, Instruments, HVAC (Heater, Air Conditioner)
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication.
Diagnostics:
Troubleshooting common issues, fault code interpretation, diagnostic procedures for various systems.
Repair:
Detailed step-by-step repair procedures for all major mechanical and electrical components, including engine, transmission, brakes, suspension, steering, and HVAC.
Overhaul:
Engine rebuild, transmission overhaul, brake caliper rebuild, suspension component replacement.
Adjustment:
Valve adjustments, clutch adjustment, steering alignment checks.
Technical Depth
Depth:
Comprehensive: Covers everything from routine maintenance and basic repairs to complex diagnostics and complete overhauls. Suitable for both DIY enthusiasts and professional technicians.
📊 Manual Specifications
File Format
File Type:
PDF
Compatibility:
All Windows versions, All Mac versions
Software Requirements:
Adobe Acrobat Reader (free download available), WinZip or WinRAR (free download available for extraction)
Print Quality
Quality:
High Definition diagrams, Readable by any Devices with PDF Reader
Printability:
Ready to Print
Binding Type
Binding:
Digital (PDF) - No physical binding
Paper Type
Paper:
N/A (Digital Format)
Features
Navigation:
Bookmarks for every chapter, Well-structured contents
Installation:
No need to install any extra software beyond PDF reader and extraction tools.
⚙️ Engine Specifications
Primary Engine
Engine 1:
1.8L G-Lader Supercharged (G60)
Engine 1 Code:
PG (G60)
Engine 1 Displacement:
1781 cc (1.8 Liters)
Engine 1 Power:
158 hp @ 5800 rpm (approx.)
Engine 1 Torque:
166 lb-ft @ 4000 rpm (approx.)
Engine 1 Fuel System:
Digifant Electronic Fuel Injection with G-Lader supercharger
Engine 1 Notable Features:
G-Lader (scroll-type supercharger), intercooled induction.
Secondary Engine
Engine 2:
2.8L VR6 (VR6, SLC)
Engine 2 Code:
AAA (VR6)
Engine 2 Displacement:
2791 cc (2.8 Liters)
Engine 2 Power:
178 hp @ 5800 rpm (approx.)
Engine 2 Torque:
180 lb-ft @ 4200 rpm (approx.)
Engine 2 Fuel System:
Bosch Motronic Electronic Fuel Injection
Engine 2 Notable Features:
Narrow-angle V6 configuration, smooth power delivery.
🔧 Transmission
Standard
Transmission Standard G60:
5-speed Manual (e.g., 02A gearbox)
Transmission Standard Vr6:
5-speed Manual (e.g., 02A gearbox)
Optional
Transmission Optional G60:
4-speed Automatic (less common)
Transmission Optional Vr6:
4-speed Automatic (e.g., 096/01M gearbox)
Features
Clutch Type:
Hydraulically actuated, single dry plate
Differential:
Optional Syncro limited-slip differential (LSD) available on some models/markets, particularly early G60.
📐 Dimensions
Exterior
Length:
Approx. 4205 mm (165.5 in)
Width:
Approx. 1690 mm (66.5 in)
Height:
Approx. 1315 mm (51.8 in)
Wheelbase:
Approx. 2470 mm (97.2 in)
Weights
Curb Weight G60:
Approx. 1250 kg (2756 lbs)
Curb Weight Vr6:
Approx. 1360 kg (2998 lbs)
Cargo
Trunk Volume:
Approx. 0.237 m³ (8.4 cu ft), expandable with rear seats folded.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not specifically rated for the early 1990s models under modern testing standards, but generally considered to have good structural integrity for its era.
Active Features
ABS:
Anti-lock Braking System (ABS) typically standard on VR6 models, optional or not available on some earlier/base G60 models.
Traction Control:
Traction control (ASR) was an option on later VR6 models.
Passive Features
Airbags:
Driver's side airbag standard on most models by the mid-90s; passenger airbag typically optional or unavailable in earlier years.
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners (front).
Rollover Protection:
Reinforced A-pillars and B-pillars designed for structural rigidity.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radios with cassette players were common. Higher trims may have CD players or upgraded speaker systems. Aftermarket upgrades are prevalent.
Driver Assistance
Cruise Control:
Cruise control was typically an optional or standard feature on higher trim levels.
Connectivity
OBD Interface:
On-Board Diagnostics (OBD) system for fault code reading. Early models may use a proprietary VW diagnostic connector, later models might begin to transition towards OBD-II compliant systems depending on the exact year and market. The manual covers diagnostic procedures for these systems.
Convenience
Power Features:
Power windows, power locks, power sunroof, and power mirrors were common features, detailed within the manual's electrical system coverage.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil type used. Consult specific manual for precise intervals.
Timing Belt Replacement:
Crucial for G60 and VR6 engines. Recommended replacement every 60,000-80,000 miles or 5-7 years. Failure can cause catastrophic engine damage.
Spark Plug Replacement:
Generally every 30,000-50,000 miles, depending on plug type. VR6 may use specific long-life plugs.
Fluid Specifications
Engine Oil G60:
API SG or higher, SAE 5W-40 or 10W-40 synthetic recommended for G-Lader engines. Capacity approx. 4.5 liters (4.8 US quarts).
Engine Oil Vr6:
API SG or higher, SAE 5W-40 or 10W-40 synthetic recommended. Capacity approx. 5.5 liters (5.8 US quarts).
Coolant:
G12 or G12+ VW approved coolant. Capacity approx. 7.0-8.0 liters. Must be a silicate-free type.
Brake Fluid:
DOT 3 or DOT 4 (check specific manual). Change every 2 years.
Transmission Fluid Manual:
API GL-4 SAE 75W-90 or 80W-90 gear oil. Capacity approx. 2.0-2.5 liters.
Transmission Fluid Automatic:
VW TL 52162 (G 052 162 A1) or equivalent ATF. Check manual for specific type and capacity.
Known Issues
G60 Supercharger:
G-Lader longevity can be an issue; maintenance of the sealing strips and regular oil changes are critical. Potential for wear and reduced boost.
Vr6 Engine:
Timing chain tensioner wear, potential for oil leaks from valve cover gaskets and oil pan. Some early models may have catalyst issues.
Electrical System:
Corrosion in connectors, aging wiring harnesses, issues with power windows, central locking, and climate control systems are not uncommon.
Suspension:
Worn control arm bushings, ball joints, and shock absorbers due to age and mileage. Rear beam axle bushings can degrade.
Body Corrosion:
Rust can form in common areas such as wheel arches, rocker panels, and around the sunroof seal, especially in humid climates.
HVAC:
Aging seals and hoses for the air conditioning system, potential for failure of the blower motor or control head.
Active Spoiler:
Actuator mechanism for the rear spoiler can fail, causing it to remain in the stowed or deployed position.
📚 Vehicle History
Brand Heritage
Volkswagen History:
Volkswagen has a long-standing history of producing well-engineered, driver-focused vehicles, evolving from the Beetle to a wide range of passenger cars and performance models.
Model Evolution
Corrado Origin:
Introduced in late 1988 (as a 1989 model), the Corrado was designed to be a more premium and performance-oriented successor to the Scirocco.
Corrado Generations:
Single generation, with significant updates including the introduction of the G60 (supercharged 1.8L) and later the VR6 (2.8L) engines. US market received the 1.8L 16V (1H) before the G60 and the VR6.
Production
Production Period:
1988-1995
Manufacturing Location:
Germany (primarily Karmann factory in Osnabrück)
Key Milestones:
Introduction of G60 engine (1988/89), introduction of VR6 engine (1991/92), discontinuation of G60 in favor of 2.0L 16V and VR6 for later years.
🏆 Awards & Recognition
Recognitions
Automotive Journalism:
Often praised by automotive journalists of its era for its sharp styling and engaging handling, though the G60's supercharger complexity and the VR6's refinement were key talking points.
Design Awards:
While specific formal awards are not widely publicized, its design by Josef Kabaň was considered a significant departure and a modern interpretation of the VW coupe lineage.
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