🏷️ Basic Information Identification Make: Volkswagen Model: Corrado Year: 1991 Codes Chassis Code: 53I Model Code 1991: G60 👋 Introduction Market Position Positioning: The Volkswagen Corrado was a niche sports coupe, positioned as a premium, driver-focused vehicle with distinctive styling. This manual caters to owners and enthusiasts seeking in-depth technical knowledge for maintenance and repair. Competitive Analysis Competitors: Competed with vehicles like the Toyota MR2, Nissan 240SX, Ford Mustang, and various European sports coupes of its era. Its unique G-Lader supercharged engine set it apart. Key Features Distinctiveness: Iconic wedge-shaped design, self-adjusting rear spoiler, advanced chassis dynamics, and the unique G-Lader supercharged engine. This manual covers these specific features in detail. Manual Value Utility: Essential resource for preserving the performance and originality of a classic Volkswagen. Provides expert-level guidance for DIY repairs and professional servicing. 📋 Manual Details Coverage Areas General Coverage: Complete factory service and repair information for the 1991 Volkswagen Corrado Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Printed (typical for factory manuals of this era, often reproduced) 📖 Manual Coverage Systems Covered Engine: G60 Supercharged 1.8L (PG engine code), including maintenance, diagnostics, disassembly, assembly, and overhaul. Fuel System: G-Lader supercharger system, fuel injection (Digifant), fuel pump, injectors, fuel lines. Ignition System: Electronic ignition system, distributor, coil, spark plugs, timing. Transmission: 5-speed manual transmission (02A), clutch system, gearbox overhaul, removal and installation. Drivetrain: Front-wheel drive, CV joints, drive axles. Suspension: Front and rear suspension, struts, springs, bushings, control arms, sway bars, wheel alignment specifications. Brakes: Front and rear disc brakes, hydraulic system, brake calipers, master cylinder, ABS (if equipped). Steering: Power assisted rack and pinion steering system, steering column, tie rods. Electrical System: Wiring diagrams, battery, alternator, starter, lighting systems, fuses, relays, diagnostic connectors. Climate Control: Heating, ventilation, air conditioning (HVAC) system diagnosis and repair. Body And Interior: Body panel removal and installation, door mechanisms, glass, upholstery, trim components. Safety Systems: Seat belts, passive restraint systems (if applicable). Procedures Included Maintenance: Routine maintenance tasks, fluid changes, filter replacements, tune-up procedures. Diagnostics: Troubleshooting guides, symptom-based diagnostics, fault code identification (if applicable). Repair: Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation. Adjustments: Precise adjustment procedures for various systems, including timing, idle speed, clutch, etc. Overhaul: Detailed instructions for complete engine and transmission overhauls. Wiring Diagrams: Comprehensive electrical system wiring diagrams for easy troubleshooting. Technical Depth Depth: Comprehensive, from basic checks and maintenance to full engine and transmission rebuilds, including specialized G60 supercharger diagnostics. 📊 Manual Specifications File Format Digital Format: PDF (if digitally reproduced), High-resolution scans of original pages. Print Quality Quality: Professional reproduction with clear text and legible diagrams. Original factory printing quality. Binding Type Binding: Spiral-bound or perfect-bound for lay-flat usability (for printed versions). Paper Type Paper: Durable paper stock suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4, Supercharged Engine Code: PG Displacement: 1.8 Liters (1781 cc) Bore X Stroke: 81.0 mm x 86.4 mm Compression Ratio: 8.1:1 Performance Horsepower: 158 PS (156 hp; 116 kW) @ 5800 rpm Torque: 225 Nm (166 lb-ft) @ 4200 rpm Fuel System Injection System: Bosch Digifant Electronic Fuel Injection Supercharger: G-Lader (Scroll-type supercharger) Fuel Type: Unleaded gasoline (91 Octane or higher recommended) 🔧 Transmission Standard Type: 5-speed Manual Transmission (02A) Optional Type: None for 1991 model year in North America. Some markets may have offered an automatic option on other models/years. Features Clutch: Hydraulically actuated single dry plate clutch Transmission Fluid Type: VW G 052 171 A1 or equivalent (e.g., SAE 75W-90 GL-4 gear oil) 📐 Dimensions Exterior Length: 4040 mm (159.1 in) Width: 1690 mm (66.5 in) Height: 1310 mm (51.6 in) Wheelbase: 2440 mm (96.1 in) Weights Curb Weight: Approx. 1210 kg (2668 lbs) 🛡️ Safety Features Ratings Crash Test Data: Limited public crash test data specific to the 1991 Corrado is available; however, Volkswagen's engineering focused on occupant protection for its era. Active Features ABS: Anti-lock Braking System (ABS) typically standard or optional on higher trims. Passive Features Seat Belts: Three-point inertia-reel seat belts with pre-tensioners (front), lap belts (rear). Airbags: Driver's side airbag not standard in 1991, available as an option on some later models. Manual covers airbag system if equipped. 💡 Technology Features Infotainment Audio System: Factory radio with cassette player, typically AM/FM. Options for CD players were rare in this era. Driver Assistance Cruise Control: Optional feature, controlled via steering column stalk. Connectivity Diagnostic Port: OBD-I diagnostic connector, typically located behind a flap in the engine bay or under the dashboard. Manual details specific diagnostic procedures for this era. 🔧 Maintenance Service Intervals Oil Change: Every 7,500 miles (12,000 km) or 12 months, whichever comes first. Spark Plugs: Replace every 30,000 miles (48,000 km). Timing Belt: Replace every 60,000 miles (96,000 km) or 4-5 years. Critical procedure...