Volkswagen Corrado 1990 - 1994
General Engine
Engine Assembly (Page GR-10)
Engine code - PG
engine/transmission, adjusting
engine/transmission, mounting points
hydraulic engine/transmission, mounting points
installing
removing
tightening torques
Engine code - AAA
engine/transmission mounting points
installing
removing
tightening torques
Volkswagen Corrado 1990 - 1994
General Engine
Engine Assembly (Page 10-2)
Engine, removing
Notes
Remove engine from top with the transmission attached.
Do not disconnect
hoses or brackets from power steering pump
A/C hoses
CAUTION!
Coolant/antifreeze must not be reused when replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.
disconnect battery ground strap
remove power steering pump and attach to body
remove compressor mounting bolts together with mount and move to one side
unscrew condenser from radiator, and move to one side
attach engine sling as shown and take weight with crane
CAUTION!
Use cotter pins on hooks and holding pins (arrows) to secure tool.
Pulley side lower ( ) second hole in vertical at position .
left arrow 2
Flywheel side lower ( ) second hole in vertical bar at position .
right arrow 6
The positions marked 1-4 on the bar must be towards the pulley side. The holes in the hooks are
counted from the hook.
upwards
CAUTION!
Guide engine carefully when lifting to avoid damage to body.
mount engine onto work bench with engine mount if it is to be disassembled
VW 540
Volkswagen Corrado 1990 - 1994
General Engine
Engine Assembly (Page 10-3)
Engine, installing
Install in reverse order of removal. Note the following:
check clutch release bearing for wear, replace if necessary
lubricate clutch release bearing, driveshaft lightly with MoS2 grease
check and ensure that the dowels for centering engine/transmission are in cylinder
block
replace self-locking nuts for engine mounts
lower engine onto mounts
CAUTION!
Guide engine carefully when lowering to avoid damage to driveshaft, body.
connect rear engine mount first, then connect transmission mount
loosen front engine mount and mount bracket
align all engine supports with mount bushing before tightening mount bolts
adjust accelerator cable (see repair group 20)
reconnect all electrical connections (see repair group 97)
check and adjust shift linkage (see repair group 34)
fill coolant (see repair group 19)
check and adjust engine oil level (see repair group 17)
adjust engine timing/idle (see Repair Group 28)
check and adjust headlights, if necessary
Volkswagen Corrado 1990 - 1994
General Engine
Engine Assembly (Page 10-4)
Tightening torques
Engine to transmission
M10 45 Nm (33 ft lb)
M12 55 Nm (41 ft lb)
Driveshaft to flange 45 Nm (33 ft lb)
Exhaust pipe to exhaust
manifold 40 Nm (30 ft lb)
Power steering pump to
mounting bracket 25 Nm (18 ft lb)
Engine/transmission mounting points
= 25 Nm (18 ft lb)
a
= 30 Nm (22 ft lb)
b
= 60 Nm (44 ft lb)
e
Hydraulic engine/transmission mounting points
= hydraulic mount
1
= 30 Nm (22 ft lb)
b
= 60 Nm (44 ft lb)
e
= 70 Nm (53 ft lb)
f
Volkswagen Corrado 1990 - 1994
General Engine
Engine Assembly (Page 10-5)
Engine/transmission, adjusting
Adjustment is necessary only if engine/transmission is removed, or mounts are loosened from
engine/transmission.
loosen bolts ( ) from engine mount
arrows A
loosen bushing on transmission mount ( )
B arrows
loosen front engine mount and mount bracket ( )
arrows
lightly rock or shake engine to adjust position
re-tighten bolts in same sequence
Volkswagen Corrado 1990 - 1994
General Engine
Engine Assembly (Page 10-6)
Engine, removing/installing
Removing
Engine code AAA
Notes
Remove engine from top with transmission attached.
CAUTION!
Wait at least 20 seconds after switching off ignition before disconnecting battery. This will
allow the platinum hot-wire in Air Mass Sensor (G 70) to burn itself clean.
CAUTION!
Always switch off ignition when disconnecting/reconnecting battery, or any part of
Motronic ignition wiring system to prevent damage to Motronic control unit (J 220).
CAUTION!
Always obtain radio security code before disconnecting battery ground strap.
switch off ignition
disconnect battery ground strap
Notes
Ensure all removed electrical wiring, tie wraps, are reinstalled and positioned as originally placed.
remove air cleaner housing
remove front lock support, see Repair Group 50
remove front bumper, see Repair Group 63
CAUTION!
Coolant/antifreeze must not be reused when replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.
remove radiator
save coolant for reuse, when applicable
Volkswagen Corrado 1990 - 1994
General Engine
Engine Assembly (Page 10-7)
Manual transmission
unbolt and disconnect hydraulic clutch cylinder
disconnect shift cable and support bracket
Automatic transmission
unclip and disconnect selector lever cable
screw in a long 8.0 mm bolt into a threaded hole on tensioner to release poly-
A
ribbed belt tension
Notes
In order to prevent damage to tensioner, only screw in bolt sufficiently to release belt tension.
remove poly-ribbed belt from power steering pump. A/C compressor
CAUTION!
Do not kink or disconnect A/C refrigerant lines.
If A/C refrigerant system is opened or requires service refer to repair group 87 for
CAUTIONS, WARNINGS and procedures.
remove A/C compressor and secure to body or frame
CAUTION!
Do not kink power steering hoses.
remove power steering pump from bracket and secure to body or frame, see Repair
Group 48
remove ignition cable guides and ignition cables ( )
arrows
remove ignition distributor cap
remove trim cover over cylinder head covers, and disconnect accelerator cable at
throttle body and cable guide
disconnect 42-point connector from engine wiring harness
remove and disconnect all other alternator, starter and transmission electrical wiring,
and lay to one side
pull off all coolant, vacuum and intake hoses from engine
disconnect inlet and return fuel lines at fuel distributor
Volkswagen Corrado 1990 - 1994
General Engine
Engine Assembly (Page 10-8)
Notes
Carefully cover any open fuel lines to prevent spillage and contamination.
disconnect oxygen sensor and front exhaust pipe, see Repair Group 26
disconnect and secure axle shafts
attach engine sling as shown and take weight with crane
CAUTION!
Use cotter pins on hooks and holding pins (arrows) to secure tool.
Pulley side ( )
left arrow
fourth hole in vertical bar at position
1
( )
center arrow
Flywheel side ( )
right arrow
fourth hole in vertical bar at position
8
The positions marked 1-4 on the bar must be towards the pulley side. The holes in the vertical bar
are counted from the hook.
upwards
unbolt engine from engine carrier at front
CAUTION!
Guide engine carefully when lifting to avoid damage to body.
mount engine onto work bench with engine mount if it is to be disassembled
3269
Installing
CAUTION!
Part numbers are for reference only. Always check with your Parts Department for latest
information.
check clutch release bearing for wear, replace if necessary
lubricate clutch release bearing driveshaft lightly with grease
G 000 100
do not lubricate release bearing guide sleeve
Volkswagen Corrado 1990 - 1994
General Engine
Engine Assembly (Page 10-9)
check and ensure that the dowels for centering engine/transmission are in cylinder
block
WARNING!
DO NOT re-use any fasteners that are worn or deformed in normal use. Many fasteners are
designed to be used only once and become unreliable and may fail when used a second
time. This includes, but is not limited to, nuts, bolts, washers, self-locking nuts or bolts,
circlips, cotter pins. Always follow recommendations given in this publication. For
replacements always use new parts.
CAUTION!
Guide engine carefully when lowering to avoid damage to driveshaft, body.
lower engine onto mounts
ensure tabs ( ) fit into opening ( ) on engine mounts
arrows A arrows B
handtighten engine and transmission carrier bolts approximately 5 to 6 turns
lightly rock or shake engine to adjust position
fully tighten engine and transmission carrier bolts
install V-belt, see Repair Group 13
reconnect all electrical connections, see appropriate wiring diagram
adjust accelerator cable, see Repair Group 20
refill coolant, see Repair Group 19
check engine timing, see Repair Group 28
not adjustable
check and adjust engine oil level
check and adjust shift linkage, see Repair Group 34
check and adjust headlights, if necessary
Volkswagen Corrado 1990 - 1994
General Engine
Engine Assembly (Page 10-10)
Tightening torques
Engine support to body 50 Nm (37 ft lb)
Engine to transmission
M 10 60 Nm (44 ft lb)
M 12 80 Nm (59 ft lb)
Driveshaft to flange 45 Nm (33 ft lb)
Front exhaust pipe to
40 Nm (30 ft lb)
exhaust manifold
Front exhaust pipe to
25 Nm (18 ft lb)
catalytic convertor
Power steering pump to
25 Nm (18 ft lb)
mounting bracket
Engine to engine carrier, front
= 60 Nm (44 ft lb)
A
= 55 Nm (41 ft lb)
B
Engine to engine carrier, right
= 60 Nm (44 ft lb)
A
= 25 Nm (18 ft lb)
C
Volkswagen Corrado 1990 - 1994
General Engine
Engine Assembly (Page 10-11)
Transmission to transmission carrier
= 60 Nm (44 ft lb)
A
= 30 Nm (22 ft lb)
C
= 25 Nm (18 ft lb)
D
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