Volkswagen Corrado 1990 1994 User Manual
Volkswagen Corrado 1990 - 1994
Body
Body-Front Doors (Page GR-57)
Central locking
assembly
bi-pressure pump, removing
checking
gas flap activator, adjusting
gas flap activator, removing/installing
electrical troubleshooting
master activators, removing/installing
pump/control module, location
rear lid activator, removing/installing
Door lock
checking
door lock, removing/installing
inner handle, removing
installing
re-keying locks
Front door
assembly
impact bar, removing
removing/adjusting
seal, removing/installing
Window regulator
bordering frame, removing/installing
carrier to glass, bonding
drilling out rivet
removing/installing
Volkswagen Corrado 1990 - 1994
Body
Body-Front Doors (Page 57-2)
Volkswagen Corrado 1990 - 1994
Body
Body-Front Doors (Page 57-3)
Fig. 1 Door, removing/adjusting
unscrew nut 6 and pull out bolt
remove hex head bolt 3 from upper and lower hinge part
remove door with help of a second mechanic
tightening torques:
nut
hex head bolt 3 = 55 Nm (41 ft lb)
= 3 Nm (2 ft lb)
6
Fig. 2 Window regulator, removing
lower door glass fully
unscrew door glass and pull off guide arms (
push door glass upward and wedge in place
arrows
)
Fig. 3 Drilling out rivet
drill out rivets (
mandrel
remove window regulator from bottom
Notes
Check rivet points for paint damage and apply anti-corrosion primer as required.
arrows
) with a 5 mm (13/64 in.) drill and drive out rivet shafts with a
Fig. 4 Window regulator, installing
insert window regulator in door and align with mounting holes
rivet window regulator to inner door panel (rivet Part No.
N 101 283.01
)
CAUTION!
Part numbers are listed for reference only. Always consult with the Parts Department for
latest information.
Volkswagen Corrado 1990 - 1994
Body
Body-Front Doors (Page 57-4)
Fig. 5 Door glass, removing/installing/adjusting
lower door glass fully
unscrew door glass, pull off guide arms (Fig. 2), tilt door glass toward front and
remove upward (window well seal, inner, removed)
tightening torque = 7 Nm (5 ft lb)
when installing door glass, sliding support must engage with guide rail when door
glass is installed
adjust door glass by loosely bolting door glass together with window regulator
raise door glass to top (glass will center) and tighten bolts
tightening torque = 7 Nm (5 ft lb)
Fig. 6 Window carrier to door glass, bonding
CAUTION!
Part numbers are listed for reference only. Always consult with the Parts Department for
latest information.
when repairing, area that is to be covered with adhesive should be cleaned prior to
bonding (Part No.
D 009 400 01
) and primed (glass primer Part No.
D 009 200
)
attach window carrier to door glass with adhesive, Part No.
cartridge)
prior to installation, the bonding area (window carrier/door glass) must harden for at
least 24 hours
dimensions for window carrier:
= 425 mm (16-39/64 in.)
a
= 475 mm (18-1/2 in.), curvature of glass not included
b
D 009 100 03
(small
Fig. 7 Trim frame, removing/installing
remove cover (triangular plates inside and out)
pull off edge protection 18 from flange
snap off trim frame 19 from flange trim frame
trim frame is bonded with door frame at interior lip
- adhesive surface
a
- door frame
1
- door glass
15
Volkswagen Corrado 1990 - 1994
Body
Body-Front Doors (Page 57-5)
install by inserting trim frame into rear portion of window well
push trim frame down and press onto flange from upper corner
remove protective paper on adhesive tape only after trim frame has been properly
seated
Fig. 8 Impact bar, removing
remove inner door panel and plastic moisture barrier, Repair Group 70
remove guide rail
- impact bar
4
pry off cover cap 2, remove hex head bolts
mounting opening
tightening torque = 25 Nm (18 ft lb)
and take out impact bar from
1,3
Volkswagen Corrado 1990 - 1994
Body
Body-Front Doors (Page 57-6)
Volkswagen Corrado 1990 - 1994
Body
Body-Front Doors (Page 57-7)
Fig. 1 Door handle, removing/installing
remove bolt and washer assembly
push door handle in direction of arrow and pivot out of door
when installing check washer 2 and clip 3 for damage
check tolerance (free play of door handle) between leveling piece and operating
lever. If necessary, adjust through rotating leveling piece
0.1 + 1 mm
torque fastening bolt 7 Nm (5 ft lb)
Fig. 2 Identical tumbler setting, maintaining
matching tumbler settings in vehicle can be made by rearranging tumblers
possible locking plate sizes = 1 2 3 4
C
CAUTION!
Part numbers are listed for reference only. Always consult with the Parts Department for
latest information.
Notes
Lubricate tumblers and springs with lubricant, Part No.
G 000 400
, and insert lock cylinder guide
Loading...