1 1

Volkswagen

Volkswagen Corrado 1991 Factory Service Repair Manual

Volkswagen Corrado 1991 Factory Service Repair Manual

$16.99
$16.99
Promotion Épuisé
Frais d'expédition calculés à l'étape de paiement.
Vehicle data plateRef 369411
Brand
Volkswagen
Vehicle
Cars
Models covered
Corrado, Volkswagen VW
Years
1991
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your model year? Ask us before you buy
🏷️ Basic Information
Identification
Make:
Volkswagen
Model:
Corrado
Year:
1991
Codes
Chassis Code:
53I
Model Code 1991:
G60
👋 Introduction
Market Position
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.
Competitive Analysis
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.
Key Features
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.
Manual Value
Utility:
Essential resource for preserving the performance and originality of a classic Volkswagen. Provides expert-level guidance for DIY repairs and professional servicing.
📋 Manual Details
Coverage Areas
General Coverage:
Complete factory service and repair information for the 1991 Volkswagen Corrado
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Printed (typical for factory manuals of this era, often reproduced)
📖 Manual Coverage
Systems Covered
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).
Procedures Included
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.
Technical Depth
Depth:
Comprehensive, from basic checks and maintenance to full engine and transmission rebuilds, including specialized G60 supercharger diagnostics.
📊 Manual Specifications
File Format
Digital Format:
PDF (if digitally reproduced), High-resolution scans of original pages.
Print Quality
Quality:
Professional reproduction with clear text and legible diagrams. Original factory printing quality.
Binding Type
Binding:
Spiral-bound or perfect-bound for lay-flat usability (for printed versions).
Paper Type
Paper:
Durable paper stock suitable for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4, Supercharged
Engine Code:
PG
Displacement:
1.8 Liters (1781 cc)
Bore X Stroke:
81.0 mm x 86.4 mm
Compression Ratio:
8.1:1
Performance
Horsepower:
158 PS (156 hp; 116 kW) @ 5800 rpm
Torque:
225 Nm (166 lb-ft) @ 4200 rpm
Fuel System
Injection System:
Bosch Digifant Electronic Fuel Injection
Supercharger:
G-Lader (Scroll-type supercharger)
Fuel Type:
Unleaded gasoline (91 Octane or higher recommended)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (02A)
Optional
Type:
None for 1991 model year in North America. Some markets may have offered an automatic option on other models/years.
Features
Clutch:
Hydraulically actuated single dry plate clutch
Transmission Fluid Type:
VW G 052 171 A1 or equivalent (e.g., SAE 75W-90 GL-4 gear oil)
📐 Dimensions
Exterior
Length:
4040 mm (159.1 in)
Width:
1690 mm (66.5 in)
Height:
1310 mm (51.6 in)
Wheelbase:
2440 mm (96.1 in)
Weights
Curb Weight:
Approx. 1210 kg (2668 lbs)
🛡️ Safety Features
Ratings
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.
Active Features
ABS:
Anti-lock Braking System (ABS) typically standard or optional on higher trims.
Passive Features
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.
💡 Technology Features
Infotainment
Audio System:
Factory radio with cassette player, typically AM/FM. Options for CD players were rare in this era.
Driver Assistance
Cruise Control:
Optional feature, controlled via steering column stalk.
Connectivity
Diagnostic Port:
OBD-I diagnostic connector, typically located behind a flap in the engine bay or under the dashboard. Manual details specific diagnostic procedures for this era.
🔧 Maintenance
Service Intervals
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).
Fluid Specifications
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.
Known Issues
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.
📚 Vehicle History
Brand Heritage
Heritage:
Volkswagen has a long history of producing iconic and innovative vehicles, from the Beetle to the Golf GTI. The Corrado built upon this heritage, offering a more sophisticated and performance-oriented coupe.
Model Evolution
Design Origin:
Designed by Giugiaro, with later refinements by VW designers. Successor to the Scirocco.
Engine Development:
Introduction of the G60 engine marked a significant technological step for Volkswagen, featuring its unique supercharger design.
Production
Production Years:
1988-1995
Manufacturing Location:
Germany
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Named to Car and Driver's Ten Best list in 1990.
Ratings
Styling Appreciation:
Consistently praised for its distinctive styling and aerodynamic profile by automotive journalists and enthusiasts.

Delivery & file format

This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.

Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

Afficher tous les détails
  • Instant download Link on the order page and in your inbox within a minute.
  • Secure checkout Encrypted Shopify payments — card, PayPal, Apple Pay, Google Pay.
  • Print-ready PDF Searchable text; print only the pages you take to the bench.
  • Coverage check Not sure it fits? Send the model and VIN before you buy.