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    Vw Corrado Service Manual

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    171 views1,060 pages

    VW Corrado Service Manual

    Uploaded by

    Robert Frimu

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    Volkswagen Corrado Official Factory Repair Manual 1990, 1991, 1992, 1993, 1994 including G60, VR6 and SLC Contents i Vehicle Care Paget Owner Information Doxityourselt Service aa Technical Description 31 Gas Station information S40 Maintenance/Lubreation Schedules a General Ropalr Group 00 General Engine—Assembly 10 Engine —CrankshatiCrankcase 13 Cylinder HeadiValve Drive 45 — Lubrication System... 7 —Cooling System 19 Fuel Systems eee Ay Supercharger Ful nection AFC Stem 2 Exhaust Exhaust Systom—Emision Conte lectrical—Battery, Starter, Generator 27 Engine Electrical 'gnition System oot} Chiich ~ 30 Clutch Torque Converter... 32 Transmission Manual Transmission —Controis, Assembly 34 Manual Transmission—Case, Gears, Shafts 235 ‘Automatic Transmission—Contrls, Housing 37 ‘Automatic Transmission—Case, Gears, Shafts 138 Differentiat—Manual Transmission C39 Automatic Transmission 39 Front Wheel Suspension —Shatts & AK 40 Suspension Rear Wheel Suspension—Shats & Axle 42 Wheels, Tires, Wheel Alignment Daa Brakes rake “Mechanic! Compares 6 Steering Brake Hydraulic Components, Regulator, Booster lar StOCHING sn eeeeeews ees 48 Body ~ 50 Body Hoodsitids 55 Body—Front Doors 57 Sunroot ‘60 Bumpers. 63 Glass, Window Rlegulators "64 Body Accessories Exterior 66 Body Accessories—Interior 68 Trim—Interior 70 Body—Seats n Heater eel = Air Conditioner i Electrical System—Instruments 0 Electrical —Raadio, Mult-function indicator 8 —Windshield Wiper & Washer 2 —Lignts 94 wiring 97 i Tandon. er Wiring Diagrams General iniormation ree Appendi: ‘On-Board Diagnostic Repair Group 01 (02) Motronic Ignition system_—VR6 engine code AAA. 28 Supplement ‘Automatic Transmission 096 Shifiock It. 37 ‘Ai Conditioning Systems using Ri134a refrigerant 87 Wiring Diagrams VvvouoVvTIvvvvVvTvTvo Vv Www Foreword Service to Volkswagen owners is a top prioiy of the Volkswagen organization that has always included the continuing davelopment and introduction of new and expanded services. In line with this purpose, Robert Bertley, Inc., in cooperation with Volkswagen United States, Inc, has introduced this Volkswagen Official Factory Repair Manual This Volkswagen Corrado manual covers the model years 1990, 1991, 1992, 1999 and 10994, It includes Volkswagen Corrado, Corrado G60, Corrado VRS and Corrado SLC. This manual was created specifically to cover only those models built for sale in tho United States ‘and Canada, For the Volkswagen owner with basic mechanical skills and for independent auto service professionals, this manual includes all the specifications and procedures that were available in an authorized Volkswagen desler service department as this manual wont to pross. The Volkswagen owner who has no intention of working on his or her car will find that owning and raferring to this manual will make it possible to be better informed and to moro knowlodgeably discuss repairs with a professional automotive sorvice technician. This manual has been propared trom the information that the Volkswagen organization provides to its own factory-trained technicians and has also been developed primarily with the professional automotive technician in mind, The aim throughout has been clarity and completeness, with step-by-step procedures and accurate specifications. The Volkswagen owner intending to do maintenance and repair should have screwdrivers and a set of metric wrenches, sockets and hex wrenches, since these basic hand tools are needed for most of the work described in this manual. Most procedures will ‘also require a torque wrench to ensure that fasteners are tightened properly and in accordance with specications. Special tools that may be required for a particular repair procedure are usualy identified by their Volkswagen special tool number and illustrated. A ‘thorough review of each procedure is racommonded to determine in advance the need for particular tools and for essential replacement parts such as gaskets. ‘Some of the information in this manual applies only to cars of a particular model year or range of years. For example, "my. 1990" refers to the 1990 modal year. Tho model yoar doos not necessatily match the calender yoar in which the car was manufactured or sold To be sure of the model year of a particular car, check the vehicle identification number (VIN) on tho car, Technical changes made in production are identified in this manual by listing the date of manufacture of the VIN forthe first car produced with this change. The VIN is @ unique sequence of 17 characters that identity each individual car, WVWDB4502NK005678 for example. Each of the 17 letters and numbers indicates certain facts about the car and its manufacture. The 7th and &th characters are Volkswagen's model ‘designation. The letter in the 10th space indicates model year: “L” for 1990 models, "M" for 1991 and so on. The letters “O" and "A" are not used, so the sequence skips to “P” for 1993 and “R’ for 1994, The last six digits are the unique sequential production number. References to VIN in this manual wil often include only the last several characters, such as '502NK005678 or 50_N_005678 from the sample VIN above, ‘Your Volkswagen's VIN can be found on a plate mounted on the top of the instrument panel, on the driver's side where the number can be seen through the windshield, and on fan identification label in the luggage compartment. This manual covers Volkswagen Corrado, Corrado G60, Corrado VAG and Corrado SLC from model years 1990, 1991, 1992, 11988 and 1994, with these VINs: ‘oe WPL TIOL-TE- PPTL] » (MM 1-1-1115 soot: TELM TTR] fy) soz OC -Ts[o[-WETe(leefo) » fvwoC 1-151 -WI-EPlI5 sos MOTEL lPLOPPT|] © MYT PT-F1- P| sooe fMOETIEELIAL-PPPIAL| © MMOL) [AERP Parts of this manual apply only to cars with certain engines or other special equipment. Most pages are cleatly labeled to indicate the engine or equipment to which the information ‘applies, Refer to the equipment code and type information in Repair Group 00, and to the Index pages at the beginning of each Repair Group. Notice also that Repair Groups 01 ‘covering on-board diagnostic capabilty and electrical troubleshooting for fuel injection, automatic transmission and antilock brakes are included as a special appendix at the back of the manual We have endeavored to ensure the accuracy of the information inthis manual. When the vast array of data presented in the manual is taken into account, however, no claim to infallilty can be made, We therefore cannot be responsible for the result of any errors that ‘may have crept into the text. The Publisher encourages comments from the readers of this ‘manual with regard to errors, and also suggestions for improvement in the presentation of the technical material. These communications have been and will be carefully considered in the preparation ofthis and other manuals. Please write to Robert Bentley, Inc., Cambridge, Massachusetts 02138, Volkswagen offers extensive warranties, especially on components of the fuel delivery ‘and emission control systems. Before deciding to repair a car that may be covered wholly or in part by any warranties issued by Vokswagen United States, Inc., consult your authorized ‘Volkswagen dealer. You may find that the dealer can make the repair either without charge or at minimal cost, Regardless of its age, or whether itis covered by warranty, your Volkswagen is an easy car to service and an easy car to get serviced. Ifat any time a repair is needed that you fee! is too dificult to do yoursel, or requires equipment that you do not have, a trained Volkswagen dealer service technician is ready to do the job for you. Robert Bentley, Inc. Before attempting any work on your Volkswagen, please turn the page to read the warnings and cautions. Also read any warning and caution that accompanies a procedure in the manual. Review the warnings and cautions on the following pages each time you prepare to work on your Volkswagen. Please read these WARNINGS and CAUTIONS before proceeding with maintenance and repair work. WARNING— ‘= Some repairs may be beyond your capability f you lack the skills, tools and equipment, or a suitable workplace for any procedure described in this manual, we suggest you leave ‘such repairs to an authorized Volkswagen dealer service department, or other qualified shop. * Volkswagen is constantly improving its cars. Sometimes these changes, both in parts and specifications, are made ‘applicable to earlier models. Therefore, before starting any ‘major jobs or repairs to components on which passenger safety may depend, consult an authorized Volkswagen ‘dealer about Technical Bulletins that may have been issued since the editorial closing of this manual. ‘+ Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used only once, and are unreliable and may fall f used a second time. This includes, but is not limited to, nuts, bolts, washers, circip ‘and cotter pins. Always replace these fasteners with new parts, * Never work under a lifted car unless itis solidly supported fon stands designed for the purpose. Do not support a car on cinder blocks, hollow tiles or other props that may crumble under continuous load, Never work under a car that is sup- ported solely by a jack. Never work under the car while the engine is running. + If you are going to work under a car on the ground, make ‘sure that the ground is level. Block the wheels to keep the car {rom rolling, Disconnect the battery negative terminal (ground strap) to prevent others from starting the car while you are under it. ‘Never run the engine unless the work area is well ventilated, Carbon monoxide (CO) kills. += Do not attempt to work on a vehicle if you do not feel well, ‘You increase the danger of injury to yourself and others if you ‘are tired, upset or have taken medication or any other sub- stance that may impair you or keep you from being fully alert, + Disconnect the battery negative (-) terminal (ground strap) whenever you work on the fuel system or the electrical sys- ‘tem. Do nat smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy. + Batterios produce explosive hydrogen gas. Keep sparks, lighted matches and open flame away from the top ofthe b tery. If hydrogen gas escaping from the cap vents is ignited, it will ignite gas trapped in the cells and cause the battery to explode. * Connect and disconnect battery cables, jumper cables or a battery charger only with the ignition switched off, to prevent sparks, Do not quick-charge the battery (for boost starting) for longer than one minute and do not allow charging voltage to exceed 16.5 volts, Wait at least one minute before boosting the battery a second time. ‘= tluminate your work area adequately but safely. Use a por- ‘table safety light for working inside or under the car. Make sure the bulb is enclosed by a wire cage. The hot flament of fan accidentally broken bulb can ignite spilled fuel or oil. ‘Tie long hair behind your head. Do not wear a necktie, a scart, loose clothing, or a necklace when you work near ‘machine tools or running engines. If hair, clothing, or jewelry ‘were to get caught in the machinery, severe injury could result. ‘Finger rings, bracelets and other jowelry should be removed ‘0 that they cannot cause electrical shorts, get caught in run- ning machinery, or be crushed by heavy parts. + Catch draining fue, oil, or brake fluid in suitable containers. Do not use food or beverage containers that might mislead ‘someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at once, but do not store the oily rags, which can ignite and burn spontaneously. ‘+ Always observe good workshop practices. Wear goggles when you operate machine tools or work with battery acid. Gloves or other protective clothing should be worn whenever the job requires working with harmful substances. * The Air-Conditioning (A/C) system is filed with chemical refrigerant, which is hazardous. The AIC system should be serviced only by trained technicians using approved retriger- ‘ant recoverylrecycling equipment, trained in related safety precautions, and familiar with regulations governing the dis- Charging and disposal of automotive chemical rerigerants. + Do not expose any part of the A/C system to high tempera- tures such as open flame. Excessive heat will increase system pressure and may cause the system to burs. ‘Some aerosol tir inflators are highly flammable. Be extremely cautious when repairing attire that may have been inflated using ‘an aerosol tire inflator. Keep sparks, open flame or other ‘sources of ignition away from the tre repair area. Inflate and deflate the tire at leas four times before breaking the bead from the rim. Completely remove the tre from the rim before attempt- ing any repair. + Friction materials such as brake or clutch discs may contain asbestos fibers. Do not create dust by grinding, sanding, o by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust. Breathing asbestos can cause seri- ous diseases such as asbestosis or cancer, and may result in death ‘Greases, lubricants and other automotive chemicals contain toxic substances, many of which are absorbed directly through the skin, Read manufacturers instructions and warn- ings carefully. Use hand and eye protection. Avoid direct skin contact. + An airbag is an explosive device. Handled improperty or with- ‘out adequate safeguards, it can be accidently activated and ‘cause serious personal injury. To prevent personal injury or air- bag system failure, only trained Volkswagen dealer service technicians should test, disassemble or service aitbag system, Please read these WARNINGS and CAUTIONS before proceeding with maintenance and repair work. WARNING (continued) — “+ ALWAYS disconnect the power supply before working on the airbag system, or when doing repairs that require remov- ing airbag system components. Disconnect the battery ‘negative (-) terminal and cover the battery. ‘The airbag unit should not be removed, nor should any work be performed on the airbag system, without first reviewing the ‘warnings and cautions that accompany the airbag system repair information in this manual. + Never apply stickers or any other coverings on the steering wheel. Do not let chemical cleaners, oil or grease come into contact with vinyl covering of the airbag unit. ‘+ Never open or otherwise attempt to repair airbag system parts. Always use new parts. Never leave airbag parts or the partially disassembled airbag system unattended. + Never use a test light or volt meter to conduct electrical tests on the airbag system. The airbag system must only be tested by trained Volkswagen Service technicians using special air- bag tester equipment. The airbag system must only be tested while its installed in the car. ‘cAUTION— + Ifyou lack the skis, tools and equipment, or a suitable work- ‘shop for any procedure described in this manual, we suggest you leave such repairs to an authorized Volkswagen dealer or ‘other qualified shop. We especially urge you to consult an authorized Volkswagen dealer before beginning repairs on any car that may sill be covered wholly or in part by any of the ‘extensive warranties issued by Volkswagen of America, nc. * Volkswagen is constantly improving is cars and sometimes these changes, both in parts and specications, are made appl- cable to earier models. Therefore part numbers in this manual are listed for reference only. Always check with an authorized ‘Volkswagen dealer parts department fo the latest information. ‘Before starting a job, make certain that you have all the nec- essary tools and parts on hand. Read all the instructions thoroughly, do not attempt shortcuts. Use tools that are appropriate tothe work and use only replacement parts meet- ing Volkswagen specifications. Makeshift tools, parts and procedures will not make good repairs. * Use pneumatic and electric tools only to loosen threaded paris and fasteners. Never use these tools to tighten fasten- ers, especially on light alloy parts. Always use @ torque wrench to tighten fasteners tothe tightening torque specifica- tion listed, + Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of the Do not pour oil onto the ground, down a drain, or into a stream, pond or lake. Consult local ordinances that govern the disposal of wastes. * Do not expose an airbag unit to temperatures above 194°F (90°C), even for a brief period, while handling it during the ‘epair process. Keep the unit clear of heat sources such as hotplates, soldering irons, heat lamps, welding equipment, or the like, + Always replace airbag system components that have been ‘mechanically damaged (bubbles, cracks, etc). + Always set down a removed airbag unit so that the horn pad Is facing upward, +The storage, transportation and disposal of airbag units are subject to the laws for flammable solids. ‘= When diving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident. ‘= When connecting cables or ground straps, all connections ‘must be cleaned to bare metal. Be sure mounting bots are tight, ‘Do not replace fuse links wih fuse links of other gauge or with ‘standard wire. Always replace the entie length ofthe fuse ink, + Before doing any electrical welding on vehicles equipped with ‘Anti-lock Brakes (ABS), disconnect the battery negative termi- nal (ground strap) and the ABS Control Module connector. On cars equipped with ABS, the ABS control unit cannot with- ‘stand temperatures from a paint-drying booth or a heat lamp in ‘excess of 203°F (95°C) and should not be subjected to temper- atures in excess of 185°F (85°C) for more than two hours. ‘On cars equipped with anti-theft radios, make sure you know the correct radio activation code before disconnecting the bat- tery or removing the radio. If the wrong code is entered into the radio when power is restored, that radio may lock up and be rendered inoperable, even if the correct code is then entered. ‘When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission Control Mod ule (TCM), the ABS Control Module, and the On-Board ‘computer. In cases where one or more of these components is ‘not separately fused, disconnect the Control Module cconnector(s) * Do not quick-charge the battery (for boost starting) for longer than one minute. Wait atleast one minute before boosting the battery a second time. x1 Index WARNING + ruomotive sores ana tepat's serous ‘semen You must be alert use commen Senso, and rose good udpemen a Frat pucora gaya coro he * Bator begining any work on our vehicle ‘horeughly read say rotor dsclamer, ‘abd he Caos and Warnings Iistod nea ‘he on of i manual, * Aina ea the comple procedure Betoreyoubogh te werk Pay special [tention o any Cautone and Warengs at fsccompary tat procedure, or ohor intrmaton ov 8 spect oe ABS ‘50 Anti-Lock Brake System or On Board Diagnostic (ABS) Ar fiter ‘888 Owner Information ‘Alignment 20 Wheels, Tres, Wheel Alignment Alternator ‘0 Eloctrical—Battery, Starter, Generator Anti-freeze ‘800 Engine—Cooling System Air Conditioner ‘Systems using R-194a refrigerant ‘see Supplement Systems using R12 refrigerant AIC compressor ‘assembly 87:22 utch checking 87:9 removinginsaling 87.28, tines instaling 87.88 shaft seal removinginstaling 87.28 valve pate, head and gasket removinginstaling 87.95 =A pressure switch checking 87.7 AC system fuses 87.7 relays location 87.8 temperatures and pressures checking 67.16 —Aircstribution and evaporator case ‘assembly 87-10, Bet and pulleys ‘assembly 87.21 Bet tensioning damper ‘assembly 87.20, —Engine component ‘mounting 87.18 Evaporator water drain valve identtyingiemaving 87.9 ‘expansion valve insulator checking 87:9 Air Conditioner (contd) Refrigerant system ‘components 87.5 discharging 87:3 ‘ll spectieatons 67 4a safely measutes 87.2 Safety elie lug idontiving 87:8 —Sight glass checking 87.8 Troubleshooting air conaitioner 6008 not coo! 87.46 ‘compressor clutch does not engage 87.48 Cooling output diminishes ater several ‘minutes 67.51 Inutiient cooing output 87.50, otroster does not clear windshield 87.44 fresh aie ‘cannot be shut of 87.39 ‘0 ae ow from dash board or foot well vents 87.42 neater inaufficent or no heat output 7.40, Vacuum system ‘checking 87-13, hose layout 87.12 removinginstaling 87.15 checking 87.14 ‘Anti-Lock Brake System (ABS) Hydraulic modulator assemaly with EDL 45.7 without EDL 45.3 removinginsialing 45.6 —Prossure warring switch removinginstaling 45.5 Repair work ‘general notes 45.2 repair ules 45.2 ATF (automatic transmission fluid) ‘8 Automatic Tansmission—Contros, Housing ‘Automatic Transmission—Case, Gears, Shaft -—tstto 3rd goar cut (K1) with turbine shaft ‘assombiy 38-130 —2ns!4th gear brake (B2) adjusting 38:90, —2roiath gear clutch (K3} With pump shaft ‘assembly 38-170 {tatip for elutch spring support replacing 98-160, ATE pump ‘assembly 38-100 —Ciutchas K1IK2 ‘adjusting'checking treoplay 38-80, isassomblng/assombling 38-140 One-way clutch with B1 piston ‘assembly 36-110 isassombling/assombling 38-120 ‘Automatic Transmission—Case, Gears, Shaft (contd) Parking lock ‘assembly 36-210 Instaling 38-220 —Planet carior ‘agustingichecking 38-60 Reverse brake (81) ‘adjustingichecking 38-70 Reverse clutch (K2) ‘assombly 26-180 CGrtip for clutch spring support replacing 38-180 Transmission assemoling 38-50, assembly 38-30 Clutchestbrakes installed postions 38-10 isassombling 36-40 selectr‘lutchvbrake engagement chart 38:20 Valve body ‘assembly 38-190 ‘disassembling/assembing 28-200 ‘Automatic Transmission—Controls, Housing (096 automatic transmis ATE cooieiATF tier tube ‘assembly 37-70 ATF iter replacing 97-80 —Automaticshitvock ‘roubieshooting 37-110 —dentfcation 00-2, 00.3 —Removinginstaling 37-60 Shit points ‘checking 37-80 —Sial speed checking 37-100 Selector loveridotent ‘segrnenvsolenoid switch adjusting 37-40 assembly 37-30 Selector mochanism ‘assembly 37-20 support removinginstaling 37:50, Techical dat chat 37-10 Battery S26 Electrical—Battory, Starter, Generator ‘or Owner Information Bolts see ElectricalBattery, Starter, Generator Body Acid ean repairing 50.11 —Body dimensions oor opening 50.4 floor section 50.2 front section 50.4 reat sacton 50:5, —Front tender adjusting 60.7 ‘mounting 50.6 xl Index Body (cont'd) —Head amp removing 50.9 Lock support assembly 50.8 removinginstaling 50.10 Shroud emovinginstaling 50.9 Body Accessories—Exterior Radiator gil emovinginstaling 66.5 Rear spolor Instating 66.5 removing 66.4 Rearview miror ‘assembly 68.7 removinginstaling 66.8, -—Rocker panel protective molsing replacing 66.9 —Roo! rim molding removing nstaling 68.3 Whee! house liner assombly 66.6 instaling 1991 my. 65.64 Body Accessories—interior Automatic shoulder belt system (USA only) ‘assombly 68.2 {600 frame track rn romovinginstling 68.4 tive unt Instaing 68.4 removing 68.3 knee bar removinginstling 68.4 knoe bar suppor bracket omovinginstaling 68.5 seat switch release magnet ‘removinginetaling 68.6 ‘shoulder bot rlease magnet Instaling 68.6 removing 68.5 Automatic shoulder belt troubleshooting (USA only) belts do not move to Ap ‘attr removing ignition key (Gtver or passenger side) 68.17 batts only move to A-pilar ‘door opened wth Key removed (Gtver o passenger) 68.18, both alts do not move to B-pllar ‘oors shut, igniton ON 68.9 belt does NOT move to A-pilar nen door opened 68.13 belt does NOT move to B-pilar 68.11, iver belt moves to A-pilar when vehicle shied into reverse 68.18 seat belt warning light comes on ‘with bots connected and ignition on 68.20 ‘seat elt waming ight does not ight bolts at pla, gniion ON 68.19 wiring diagrams 68.21 Body Accessories—interior (cont) Child seat Instaling on front passenger seat 68:31 interior miror removing fistaing 68.8 Roar soat bot assombly 68.7 buckle removinginstaling 68.8 mounting removing finstaing 68.8 Seat bots inspecting 63.28 Body—Front Doors, Cental ocking ‘assembiy 57.8 bipressure pump removing 7.10 ‘hocking 57.13 lectical troubleshooting 57.14 42s fap activator, ‘adjusting 57.118 removinginstaling 57.11 master activators removinginstaling 87.10 pumpleortr module Tocaton 57.17 rear i activator removinginstaling 67.12 Door fck checking 57.8 oor lock removinginstling 57.8 Inner handte removing 97.7 instating 87.7 looks ying 57.18 Front door assembly 57.2 impact bar moving 57.5 removinglagusting 57.3 seal removinginstaling 57.8 Window regulator ordering tame removinginstaling 57.4 carr to gas bonding 57.3 cing out vt 57.3 removinginstaling 57.3 Body—Seats —Conter armrest removingtnsaling 72.3 Front seat backrest removinginstaling 722 removingtnstaling 72.2 Rear seat backrest ‘omovinginstaling 72.4 removinghnstaling 72.3 Brake fluid ‘00 Brako—Hycraule Components Brake—Hydraulic Components, Regulator, Booster —Brake boostarimaster cylinder ‘assembly 47.13, —Brake caliper piston ro-bloeding 47.7 FemovingInstating 47.3, 47.6, 47.7, seal Femovinginstaing 47.3, 476 —Brake tid replacing with ABS 47.11 wiout ABS 47.15 Brake pressure regulator checkinglagusting 47.8 —Brake system bleeding with ABS 47.9 without ABS 47.14 —Front brake caliper ‘component layout 47.2 —Rear brake caliper ‘component layout 47.5 Brake—Mechanical Components —Brake caliper removing 46.4 —Front brake ‘assembly 48.3 acs removing/nstaling 48.4 —Brake pedal assembly 46.9, —Parking brake adjusting 46.8 assembly 46.7, Rear brake assembly 46.5. acs replacing 46.6 Techical data chart 46.2 Bumpers —Front bumper assembly 63.2 ap dimonsion 63.4 omovinginstaling 63. 3 —Rear bumper assembly 63.5, (ap dimension 63.6 removinginsaling 63.6, Central locking ‘800 Body-—Front Doors cluteh (2A S-speed manual transmission clutch ‘assembly 90.7 tomovinginstaling 30.8 '—Cuten diaphragm spring ends checking 30.8 —Cuuten pedal ‘assembly 30.2 —Cuteh release ‘assembly 30.5 Xi Index WARNING + Automotive sence and reparis serious business. You must be ale, u ommon senso and enero good {tagarnrt to prover persona ur and Eomptte ie wor safely. * Before begining any work on your ‘eh, hovugh rosa esa Tote, decanter and the Cautons and {arg tied near ne ron of "Aways ead the complete procedure belore'you beg the wor Pay speck Stenion ery Cautons sre Warrings that accompany thet procedure, orator Inomatonon's specie ope Clutch (cont'd) =Fiywhaet bol torque 90.7 —Hyerauitc components ‘assembly 30.4 —Main shaft seal ‘wig in 30.8 replacing 90.9 —Pressure plate replacing 90.9 —Retum spring removinginstaling 90.9 Troubleshooting chart 20.10, Compression pressure ‘See Engine—Cyiinder Head Valve Drive Constant velocity (CV) joints '5e0 Front Whee! Suspension—Shafs and Cruise control ‘S00 Eloctrical—Battor, Starter, Generator or Electrical Systom—Lights Cylinder block ‘See Engine—Crankshat/Crankcase Cylinder head ‘See Engine—CrankshafCrankcaso Differential—Automatio Transmission —Ae lange ol seal removinginsaling 39-10 —Difrentiat adjusting 39-190 assembly 39-80

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