vw rule 19 Posted September 15, 2019 (edited) I'll try and find as much info as possible for both these engines, and will update on this first/second post. Feel free to add any info that you know and I'll gladly update like I say this first/second post. Si ************************** According to Bentley Manual. FUEL KR & 9A The 4 Banjo bolts for the injector pipes in the fuel distributor are: 10 Nm (7 ft.Ib) Small Banjo bolt for fuel pipe to cold start valve 10Nm (7 ft.Ib) Large Banjo bolts around metering head are 20 Nm (15 ft.Ib) Small Banjo bolts around metering head are 10 Nm (7 ft.Ib) KR engine The same torque settings for large & small Banjo bolts on the fuel pressure regulator that's bolted to front of engine block on (KR) 1.8 16v Large Banjo 20 Nm (15 ft.Ib) Small Banjo 10 Nm (7 ft.Ib) 9A Engine Also the same torque settings for both fuel pipes on the fuel pressure regulator on (9A) 2.0 16v this one is bolted to side of metering head. Large pipe 20 Nm (15 ft.Ib) Small pipe 10 Nm (7 ft.Ib) But this doesn't have Banjo bolts. KR Fuel pressure = 5.2 to 5.6 bar (76 to 81 PSI) 9A Fuel pressure = 6.1 to 6.6 bar (89 to 95 PSI) KR Fuel injector opening pressure 3.0 to 4.1 bar (44 to 59 PSI) 9A Fuel injector opening pressure 3.7 to 4.8 bar (54 to 70 PSI) Retaining clamp for fuel injectors for Corrado 1.8 16v (KR) and 2.0 16v (9A) x4 are fitted. Part number 051 133 556 191 201 373 = Fuel feed pipe from external fuel pump to accumulator. (Possibly still available) 505 201 218A Fuel feed pipe from accumulator to fuel filter. (looks like this is obsolete now) Fuel Accumulator inlet M16 x 1.5mm male thread outlet M14 x 1.5mm male thread Original fuel filter inlet M14 x 1.5 female thread for (Banjo) outlet M12 x 1.5mm female thread for (Banjo) KR Inlet manifold diameter 50mm Torque setting 20Nm (15 ft.Ib) 9A Inlet manifold diameter 42mm Torque setting 20Nm (15 ft.Ib) KR engine HP 1989 to 1991 (139BHP) MK2 Golf 1990 to 1992 (136BHP) Corrado 9A engine HP Passat / Corrado 1992 to 1995 (134BHP to 136BHP) Video of the fuel system Edited October 13, 2020 by vw rule Quote Share this post Link to post Share on other sites
vw rule 19 Posted September 15, 2019 (edited) According to Bentley Manual. ENGINE Camshaft & intermediate shaft sprockets, torque setting for both 65Nm (48 ft.Ib) Intermediate shaft oil seal housing 25Nm (18 ft.Ib) Cam belt tensioner 45Nm (33 ft.Ib) Camshaft bearing caps 15Nm (11 ft.Ib) Cam cover bolts 10Nm to 12Nm (7 to 10 ft.Ib) Water pump pulley 20Nm (15 ft.Ib) Crankshaft x4 allen key bolts 20Nm (15 ft.Ib) Crankshaft front main oil seal housing M8 bolts 20Nm (15 ft.Ib) M6 bolts 10Nm to 12Nm (7 to 10 ft.Ib) Sump bolts 20Nm (15 ft.Ib) Crankshaft rear main oil seal housing M8 bolts 20Nm (15 ft.Ib) M6 bolts 10Nm to 12Nm (7 to 10 ft.Ib) ************* ************* Crankshaft main bolt (Lubricated) 6 sided bolt with washer 180 Nm (137 ft.Ib) Hex head bolt with washer 150Nm (111 ft.Ib) 12 sided bolt with collar (no washer) 90 Nm (66 ft.Ib) + 180° (half turn) ************* ************* LUBRICATION Engine oil low pressure range Switch opens from 0.5 to 0.45 bar (2.1 to 6.4 PSI) Manual says 0.3 bar is normal. Low oil pressure switch (brown 0.3 bar) Also you can get the blue one below. (Blue 0.4 bar) Part number 028 919 081H *************** Engine oil high pressure range Switch closes from 1.6 to 2.0 bar (23.2 to 29 PSI) Manual says 1.8 bar is normal. High pressure oil sensor switch (white 1.8 bar) Part number 056 919 081 Oil pressure switch torque settings 25Nm (18 ft.Ib) This is from the Bentley manual but me personally I'd say 15 ft.Ib is enough so be careful when tightening the oil pressure switches. Normal operation of oil pressure switch. When the ignition is turned on the oil warning light may flash meaning no oil pressure. Once the engine is started oil pressure should rise which opens the switch = opening the ground/earth circuit and turning the oil warning light off. When you have too low oil pressure or have a faulty switch, the oil warning light will flash or stay on, plus you might have a warning alarm buzz from your dash. Also manual says on the 16v engines that they have extra oil pray nozzles attached to base of cylinder bores, these nozzles open up at oil pressure above 3.5 bar (50 PSI) Oil temp sender Part number 049 919 563A Normally fits in back of head the side facing exhaust manifold, on top left for 9A & ABF But the KR might be on the oil filter housing. ********************************* CYLINDER HEAD Cylinder head torque settings 16v Stage 1) 40Nm (30 ft.Ib) Stage 2) 60Nm (44 ft.Ib) Stage 3) + 180° (half turn) or you can do this as two 90° turns = 180° NOTE= Always use new head bolts as they are stretch bolts Cylinder head face warpage maximum 0.1mm (.0004 in) Anymore then this and there's a possibility your head gasket may not seal. Head gasket should be the metal compression genuine VW one, as the 16v can have high compression, the other cheap pattern gaskets don't last as long. Cylinder head minimum thickness 118.1mm (4.650 in) measure the thickness of the head between where the valve cover sits and cylinder head face. Valve seat dimensions Intake 31.2mm (1.228 in) Exhaust 27.6mm (1.087 in) Valve seat angle Inlet 45° Exhaust 45° Valve head diameter Inlet 32mm (1.259 in) Exhaust 28mm (1.102 in) Valve stem diameter Inlet 6.97mm (.2744 in) Exhaust 6.94mm (.2732 in) Valve lengths Inlet 95.50mm (3.760 in) Exhaust 98.20mm (3.866 in) Valve face angle Inlet 45° Exhaust 45° **************************************** IGNITION Knock sensors KR/ PL torque settings 15 to 25Nm (11 to 18 ft.Ib) Knock sensors 9A torque settings 15 to 20Nm (11 to 15 ft.Ib) Knock sensor 1 is on left Knock sensor 2 is on right Testing value approx 300k ohms Ignition timing setting 6° + or - 1° BTDC Engine ilde speed setting Up to 1990 (700rom to 900rpm) After 1990 (800rpm to 1000rpm) Spark plug torque setting 20Nm (15 ft.Ib) Firing order = 1, 3, 4, 2 Number 1 cylinder is at the cam belt end, number 4 cylinder is closest to distributor. The engine rotates clockwise but the distributor will rotate anticlockwise. Si Edited September 29, 2019 by vw rule Quote Share this post Link to post Share on other sites
Keyo 47 Posted September 15, 2019 (edited) Thanks mate I'm going to print that off now so I dont blow up my car . Ive just ordered a new white oil switch definitely threaded the new one and it was OE VW , managed to damage £30.00 of sensors x1+ oil switch x1 as they were Buri + OE but at least learnt something today, do not work on my own car lol. Edited September 15, 2019 by Keyo Quote Share this post Link to post Share on other sites
vw rule 19 Posted September 15, 2019 Thanks mate I'm going to print that off now so I dont blow up my car . Ive just ordered a new white oil switch definitely threaded the new one and it was OE VW , managed to damage £30.00 of sensors x1+ oil switch x1 as they were Buri + OE but at least learnt something today, do not work on my own car lol. No worries. Si Quote Share this post Link to post Share on other sites
vw rule 19 Posted September 18, 2019 (edited) STEERING 1.8 16V and 2.0 16v Corrado looks like the original retaining U-clamp for left side of steering rack was 15mm wide with matching bush. Actual Width 16.5mm Thickness 5mm Inner diameter 61mm to 62mm Height inner 70mm Height outer 75mm 15mm wide U-clamp now obsolete Aftermarket 15mm bush still available. If you're able to clean up your original 15mm wide clamp, basically you don't have heavy corrosion and it's just light surface rust, then you should be ok to reuse it. ****************** Replacement retaining U-clamp is 18.5mm Part number 191 419 875 VW Heritage sell them plus some on Ebay. Actual Width 20.3mm Thickness 5mm Inner diameter 61mm to 62mm Height inner 70mm Height outer 75mm Plus you'll need the matching bush to fit the above clamp 18.5mm ******************* Power steering rack retaining flange bolts M8 X 75mm thread pitch 1.25 Thread length 40mm Size of Hex head 13mm Grade = high tensile grade 8.8 OEM Part number N901 845 02 obsolete Original flange nuts for above bolts Size of hex on nut 13mm Thread pitch 1.25 OEM Part number N902 264 04 obsolete Due to OEM rack bolts now obsolete, you can still purchase ordinary shouldered bolts, just make sure they're minimum grade of 8.8 high tensile and ideally shouldered bolts. Regarding the thread the original pitch was 1.25mm if the thread length on bolt replacement is only 25mm or 30mm long then it'll be too short, you can use a M8 die with 1.25mm to cut and extend the thread to make it 40mm long if needed. Also make sure you use nylon lock nuts, the original rack bolts and nuts were flanged ones. ****************************** CORRADO with KR Engine 1989 to 1991 Power steering oil reservoir 191 422 371C Power steering hose from reservoir to pump 535 422 881 A) Return pipe from rack to reservoir ( RHD 192 422 891A ) ( LHD 191 422 891 ) B) Feed pipe from power steering pump to rack ( RHD 192 422 893A ) ( LHD 191 422 893 ) O-ring for both main pipes above (A) and (B) 1H0 422 999 TRW Steering rack RHD up to VIN >>>50-N-011 487 ( with 36 splines ) 192 422 061P Steering column shaft (with 36 splines) 536 419 951A TRW Steering rack RHD after VIN 50-N-011 488>>> ( with 22 splines ) 192 422 061K Steering column shaft (with 22 splines) 536 419 951C Top bolt for steering column shaft ( M8 X 35mm ) N01 033 512 Nut lock nut for above bolt N10 218 708 Bottom bolt for steering column shaft ( M8 X 28mm ) N01 023 36 Track rod end right side 191 419 812 Hex lock nut for above track rod end N90 321 302 Track rod end left side 191 419 811 Hex lock nut for above track rod end N90 321 302 Nut that locks track rod end to tie rod M14 X 1.5mm N10 218 708 ************************************************* CORRADO with 9A Engine 1991 to 1995 Power steering oil reservoir 191 422 371B Power steering hose from reservoir to return pipe 535 422 888A T-Piece for above hose 191 422 929 A) Return pipe from rack to above T-Piece ( RHD 536 422 891 ) ( LHD 535 422 891 ) Return hose from above pipe to cooler pipe under radiator 535 422 889A Cooler pipe (fits under radiator) 535 422 896A Hose from cooler pipe to power steering pump 191 422 887 = up to 1993 Hose from cooler pipe to power steering pump 535 422 887E = From 1993 to 1995 B1) Feed pipe from power steering pump to rack ( RHD 536 422 893B ) ( LHD 535 422 893C ) THIS IS THE SCREWED TYPE B2) Feed pipe from power steering pump to rack ( RHD 536 422 893D ) ( LHD 535 422 893D ) THIS IS THE BANJO TYPE O-ring for both main power steering pipes above (A) and (B1) 1H0 422 999 TRW Steering rack RHD up to VIN >>>50-N-011 487 ( with 36 splines ) 192 422 061P Steering column shaft (with 36 splines) 536 419 951A TRW Steering rack RHD after VIN 50-N-011 488>>> ( with 22 splines ) 192 422 061K Steering column shaft (with 22 splines) 536 419 951C Top bolt for steering column shaft ( M8 X 35mm ) N01 033 512 Nut lock nut for above bolt N02 214 64 Bottom bolt for steering column shaft ( M8 X 28mm ) N01 023 36 Track rod end right side 191 419 812 Hex lock nut for above track rod end N90 321 302 Track rod end left side 191 419 811 Hex lock nut for above track rod end N90 321 302 Nut that locks track rod end to tie rod M14 X 1.5mm N10 218 708 Edited September 30, 2019 by vw rule Quote Share this post Link to post Share on other sites
vw rule 19 Posted October 29, 2019 (edited) Main ECU has 35 terminals for the 2.0 16v E-Motronic Bosch system (9A eng) Terminal 1 = 0.5mm grey/white wire (goes to 6 point push on connector ground behind fuse box) Then goes to 3 point push on connector behind centre console. Then goes to double white diagnostic connector plug under gear stick boot, possibly up to 1992 After 1993 it'll be the OBD2 black connector. Terminal 2 = 0.5mm blk/white wire (earth to behind fuse box) says six point push on connection. Linked to battery to body earth. Terminal 3 = 0.5mm violet/blk wire (goes to terminal 1 of coolant temp switch) in back of cylinder head. Terminal 4 = 0.5mm white/red wire (goes to terminal 1 of differential pressure regulator/governor) Terminal 5 = 0.5 brown/Black wire (goes to terminal 2 of differential pressure regulator/governor) Terminal 6 = 0.5mm white wire (goes to 3 point push on connector near starter motor) then goes to terminal 1 of knock sensor 2. Terminal 7 = (For Lambda sensor) 0.5mm to 1mm black wire leaves terminal 7 and branches off into second black wire which goes to earth point on bulkhead, main black wire though continues to Lambda sensor, plus goes to single point connection in engine bay at the back, possibly to rear engine mount? 1mm white wire from Lambda plug goes to double connection point in rear of engine bay, then goes to single connection point behind fusebox panel. Also looks like the red/yellow wire from fuel pump circuit is partly connected to Lambda sensor via white wire. BUT NEED TO DOUBLE CHECK THIS Terminal 8 = has two wires. 0.5mm blk wire and 0.5mm yellow wire. ************** Blk wire (goes to 3 point push on connector near starter motor) *************** Yellow wire (goes to 3 point push on connector near starter motor, then goes to terminal 2 of knock sensor 2. Terminal 3 of knock sensor 2 is 0.5mm blk wire says is earth goes back in ECU main wiring loom. Terminal 9 = POSSIBLY ONLY ON USA MODEL. 0.5mm blk/yellow wire (goes to terminal 1 of EGR temp sensor G98) Terminal 2 of above sensor is 0.5mm brown/yellow wire says earth goes back in ECU main wiring loom. Terminal 10 = ???? Possibly blank as not listed ???? Terminal 11 = 1.5mm grey wire (goes to terminal 2 of ignition module. Terminal 12 = 0.5mm to 1mm red/yellow wire goes to fuel pump relay. Terminal 13 = 0.5mm yellow/blk wire (goes to 4 point push on connector behind fuse box) then goes to double blue diagnostic connector under gear stick possibly up to 1992 After 1993 it'll be the OBD2 black connector. Terminal 14 = 1.5mm blk wire (goes to 5 point push on connector behind fuse box) Then comes back out as 1mm blk wire, looks like an earth. Changes to 1.5mm blk/yellow wire (goes to 6 point push on connector behind fuse box) which links to terminal 1 of ignition module. Terminal 15 = 0.5mm green/yellow wire (goes to terminal 2 of carbon canister solenoid valve 2) Terminal 1 of solenoid valve is 0.5mm blk/white wire, says earth connection goes back in ECU main wiring loom. Terminal 16 = 0.5mm brown/red wire (goes to terminal 2 of cold start valve injector) Terminal 1 of cold start valve is 0.5mm blk/white wire, says earth connection goes back in ECU main wiring loom. Terminal 17= 1mm white wire (goes to terminal 1 of idle control valve) Terminal 2 of idle valve is 1mm blk/white wire, says earth connection back in ECU main wiring loom. Terminal 18 = 1.5mm brown/yellow wire (goes through ECU main wiring loom, where it changes to 2.5mm brown wire and 0.5mm brown wire. (Says ?? 2.5mm goes to THIS I'VE GOT TO TRACE YET ?? (Says 0.5mm goes to terminal 2 of carbon canister solenoid valve 1) Terminal 1 of solenoid valve 1 is 0.5mm blk/white wire, says earth connection back in ECU main wiring loom. Terminal 19 = 1.5mm red wire (looks like this is main live power to ECU) says goes to 2 point push on connector behind fuse box. Terminal 20 = ???? Possibly blank as not listed ???? Terminal 21 = 0.5mm red/blk wire (goes to terminal 3 of hall sensor) Terminal 1 of hall sensor = is 0.5mm brown/white wire = says earth goes back in ECU main wiring loom. This hall sensor is inside the ignition distributor = should have a 3 pin connector plug. Terminal 22 = 0.5mm yellow wire (goes to 5 point push on connector behind fuse box = says earth connection) then goes to 2 point push on connector behind centre console. Then goes to single white diagnostic connector under gear stick boot. possibly up to 1992 After 1993 it'll be the OBD2 black connector. Terminal 23 = 0.5mm grey/green wire (goes to terminal 2 of air flow sensor) Terminal 3 of above sensor = 0.5mm brown/white wire - says is earth connection goes back in ECU main wiring loom. Terminal 24 = Grey wire (goes to one point connector near starter motor) Then goes to terminal 1 of knock sensor 1 Terminal 25 = ???? Possibly blank as not listed ???? Terminal 26 = 0.5mm grey/red wire (goes to terminal 1 of air flow sensor. Terminal 27 = Green wire (goes to ignition timing reference sensor/knock control sensor) this is normally connected onto HT lead number 4. Only on 16v eng. Terminal 28 = 0.5mm black/blue wire goes to terminal 1 of throttle position switch. Terminal 29 = Red wire (goes to ignition timing reference sensor/knock control sensor) this is normally connected onto HT lead number 4. Only on 16v eng. Terminal 30 = 0.5mm green/white wire (goes to terminal 2 of hall sensor) This hall sensor is inside the ignition distributor = should have a 3 pin connector plug. Terminal 31 = ???? Possibly blank as not listed ???? Terminal 32 = 0.5mm grey wire goes to pin 3 of throttle position switch. Pin 2 of switch is 0.5mm brown/white wire that goes back into main ECU wiring loom, possibly an earth. Terminal 33 = 0.5mm blk/green wire (goes to 2 point push on connector behind fuse box. Terminal 34 = 0.5mm white/green wire (goes to 3 point push on connector behind fuse box) Then changes to 0.5mm brown/red wire = says goes to white 12 pin connector plug with central rear location tab, terminal/pin 6 of white 12 pin plug. Terminal 35 = 1mm brown wire (looks like this is one of the main earth connections for ECU) looks like it goes to valve cover on back right, close to where the distributor is. This is now all 35 terminal/pins listed for the 2.0 16v main fuel/ignition ECU. Si Edited November 10, 2019 by vw rule Quote Share this post Link to post Share on other sites
Geeba 0 Posted October 29, 2019 Gesssss amazing info! Any chance you can shoot round mine and get the engine back in for me LOL! you'll save a day in looking up what goes where! ;) Quote Share this post Link to post Share on other sites
vw rule 19 Posted October 29, 2019 Gesssss amazing info! Any chance you can shoot round mine and get the engine back in for me LOL! you'll save a day in looking up what goes where! ;) For a few beer tokens why not :lol: What flavor is your Corrado ? I don't mind doing another thread/s for the G60 and VR6 if it helps others ? Si Quote Share this post Link to post Share on other sites
vw rule 19 Posted October 12, 2020 (edited) Diagrams from the Bentley Manual for the 2.0 16v (9A) electrical circuit for the ECU, I have already listed most of them in a previous post, but thought these wiring diagrams may help also. Green dots show ECU pins. Si Some info here regarding the Lambda sensor on the 9A Edited October 13, 2020 by vw rule 1 Quote Share this post Link to post Share on other sites
