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.
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.
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.
Utility:
Essential resource for preserving the performance and originality of a classic Volkswagen. Provides expert-level guidance for DIY repairs and professional servicing.
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).
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.
Depth:
Comprehensive, from basic checks and maintenance to full engine and transmission rebuilds, including specialized G60 supercharger diagnostics.
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.
ABS:
Anti-lock Braking System (ABS) typically standard or optional on higher trims.
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.
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 due to interference engine design.
Coolant Flush:
Every 2-3 years or 30,000 miles (48,000 km).
Engine Oil:
SAE 5W-40 or 10W-40 synthetic or semi-synthetic oil meeting VW 500 00 or 502 00 specifications.
Coolant:
G11 antifreeze (blue) mixed with distilled water (50/50 ratio).
Brake Fluid:
DOT 4 brake fluid.
G Lader Maintenance:
Requires specific G-Lader oil changes (usually every 30,000 miles). Seal wear and oil leaks can occur.
Electrical Issues:
Aging wiring harnesses, corrosion in connectors, and failing relays are common. Digifant ECU can also be prone to failure.
Suspension Wear:
Worn control arm bushings, ball joints, and strut mounts are typical for high-mileage vehicles.
Body Rust:
Can be susceptible to rust, particularly around wheel arches, sills, and sunroof (if equipped).
Window Regulators:
Power window regulator mechanisms can fail over time.
