Volkswagen Corrado 1990 - 1994

Fuel Systems Supercharger Exhaust Engine Electrical

Supercharger (Page GR-21)

G-charger

boost pressure component layout damage, repairing

Safety precautions

chart

Volkswagen Corrado 1990 - 1994

Fuel Systems Supercharger Exhaust Engine Electrical

Supercharger (Page 21-10-1)

Before starting repairs, see Safety Precautions, section 21-20 .

Notes

secure ALL hose connections with clamps replace ALL seals and sealing rings air system must be sealed

Volkswagen Corrado 1990 - 1994

Fuel Systems Supercharger Exhaust Engine Electrical

Supercharger (Page 21-10-2)

Volkswagen Corrado 1990 - 1994

Fuel Systems Supercharger Exhaust Engine Electrical

Supercharger (Page 21-20-1)

Safety Precautions

Rules of Cleanliness

When working on fuel system, always follow precautions on cleanliness below: thoroughly clean all unions and area near connections before disconnecting place removed parts on a clean surface and cover over. Use paper or plastic sheet.

Do NOT use fluffy cloths.

components which have been opened or disassembled must be covered or sealed carefully if repair cannot be carried out immediately only install clean components only unpack replacement parts immediately before they are installed do NOT use parts that have been stored loose (for instance, in toolboxes) when fuel system is open, do NOT work with compressed air if this can be avoided or move car unless absolutely necessary

System Precautions

CAUTION!

When working on vehicles with Digifant fuel/ ignition system, observe the following precautions to prevent personal injury and/or damage to the ignition system: connect/disconnect ignition system wires (including high tension wires and test instrument wires) only when the ignition is switched OFF do NOT crank engine before high tension wire of ignition distributor (terminal

4) is connected to ground with jumper wire do NOT use battery booster longer than 1 minute or exceed 16.5 Volts with booster do NOT wash engine unless the ignition is switched OFF disconnect battery completely when arc or spot welding do NOT connect condenser to terminal 1 do NOT substitute rotor of ignition distributor or radio noise suppressor with one of different type when installing suppressor, use only 1000 Ohms for high tension wires and

5000 Ohms for spark plug connectors do NOT allow terminal 1 of coil to contact ground. Possible destruction of the control unit could result

Volkswagen Corrado 1990 - 1994

Fuel Systems Supercharger Exhaust Engine Electrical

Supercharger (Page 21-30-1)

Boost pressure, checking

Check these first idle setting OK (checking, see repair Group 24 ) knock sensor OK (checking, see repair Group 28) engine oil temperature 80 C (176 F) minimum connect pressure gage VW 1397 to pressure regulator using T adaptor open pressure gage check valve to position A start engine and run at idle remove harness connectors from CO potentiometer and temperature sensor (in front flange on cylinder head, color code blue) accelerate to full throttle engine speed must increase periodically and then drop (surges) observe pressure gage boost pressure must reach 0.6 bar (8.7 psi) at high engine speed

If NO check air system for leakage, check bypass setting, see Repair Group 24 and/or replace G-charger

Volkswagen Corrado 1990 - 1994

Fuel Systems Supercharger Exhaust Engine Electrical

Supercharger (Page 21-40-1)

G-charger damage, repairing

CAUTION!

Strictly observe Rules of Cleanliness when working on or assembling components in the

G-charger system.

If the G-charger is damaged by foreign material entering the inlet air system, perform the following steps BEFORE replacing the G-charger thoroughly clean air filter housing replace air filter element replace intercooler replace silencer clean G-charger connecting hoses, if cleaning not possible, replace replace seals and sealing rings replace air bypass tube check for filter screen in air bypass tube

If no filter screen repair is complete

If filter screen installed check air bypass tube for foreign material

If present thoroughly clean intake manifold (inside) remove cylinder head, see Repair Group 15 for additional information on this topic carefully inspect cylinder head for obvious damage and stress induced damage resulting from foreign material, repair or replace as necessary inspect piston and cylinder walls for foreign material damage, repair or replace as necessary

Volkswagen Corrado 1990 - 1994

Fuel Systems Supercharger Exhaust Engine Electrical

Supercharger (Page 21-50-1)

Boost pressure system, leak checking

Notes

By using leak tester tool VAG 1687, Test A will completely check the inlet air system for leakage.

The following tests are performed with the engine not running.

Test A

If there is still leakage after performing Test A perform Test B

Test A leak-checks the following:

G-charger including silencer connecting hoses between silencer and intercooler connecting hoses between intercooler (with CO potentiometer G 74) and by-pass by-pass tube between G-charger and by-pass connecting hose to carbon canister shut-off valve throttle intake manifold fuel injector sealing at seat

Volkswagen Corrado 1990 - 1994

Fuel Systems Supercharger Exhaust Engine Electrical

Supercharger (Page 21-50-2)

remove camshaft drive belt cover from above engine

A: position crankshaft at TDC for cylinder 1 .

B: camshaft cover marking must be between dots on cam gear.

note position of camshaft gear dots turn back camshaft gear approx. 3 teeth by turning crankshaft counterclockwise remove crankcase ventilation hose from pressure regulator valve and seal off using adaptor VAG 1687/4 tighten hose to adaptor using two hose clamps 1 remove intake air hose flange from G-charger install adaptor VAG 1687/2

Volkswagen Corrado 1990 - 1994

Fuel Systems Supercharger Exhaust Engine Electrical

Supercharger (Page 21-50-3)

close valves 2, 3, 4 on VAG 1687 leak tester, drain viewing glass if necessary using drain screw 6 connect shop air 1 to VAG 1687 leak tester connect pressure hose 5 to tester using adaptor VAG 1687/2 open valve 3 adjust pressure on valve 2 to 0.9 bar cap pushed upwards open valve 4 until the boost pressure circuit (air path) is pressurized regulate using valve 2 until 0.9 bar pressure is obtained close valve 3 and observe pressure drop pressure build-up must not exceed 0.9 bar observe pressure after 30 seconds pressure must not be less than 0.3 bar

If YES determine source of leak by listening, feeling or by applying a commercial leak detector spray

Notes

A slight air leak near the top toothed gear of the G-charger does not affect boost pressure. This area is not connected to the boost system when the engine is running.

release the applied pressure before removing the adaptor by removing the coupling from adaptor VAG 1687/2

Volkswagen Corrado 1990 - 1994

Fuel Systems Supercharger Exhaust Engine Electrical

Supercharger (Page 21-50-4)

Test B

Test B leak-checks the following:

G-charger with silencer connecting hoses between silencer and intercooler connecting hoses between intercooler (with CO potentiometer G 74) and throttle body

A : disconnect by-pass tube at G-charger and install adaptor VAG 1687/1

B : disconnect intercooler hose from throttle body plug off hose opening using adaptor VAG 1687/3 tighten hose to adaptor using hose clamp close valves 2, 3 , and 4 on leak tester VAG 1687

connect air pressure hose 5 to adaptor VAG 1687/2 open valve 3 adjust pressure on valve 2 to 0.9 bar with cap pushed upwards

Volkswagen Corrado 1990 - 1994

Fuel Systems Supercharger Exhaust Engine Electrical

Supercharger (Page 21-50-5)

open valve 4 until the boost pressure circuit (air path) is pressurized regulate using valve 2 until 0.9 bar pressure is obtained close valve 3 and observe pressure drop pressure build-up must not exceed 0.9 bar observe pressure after 40 seconds pressure must not be less than 0.3 bar

If YES determine source of leak by listening, feeling or by applying a commercial leak detector spray release the applied pressure before removing the adaptor by removing the coupling from adaptor VAG 1687/2 perform Test A to check for leakage