technical specifications VOLKSWAGEN CORRADO 1990 Repair Manual

STEERING COLUMN SWITCHES
Article Text (p. 3)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:51PM
follow air bag service precautions may result in air bag
deployment and personal injury. See SERVICE PRECAUTIONS.
After component replacement, perform a system operational
check to ensure proper system operation. See SYSTEM
OPERATION CHECK.
Removal
1) Before proceeding, follow air bag service precautions. See
SERVICE PRECAUTIONS. Disable air bag system. See DISABLING &
ACTIVATING AIR BAG SYSTEM.
2) Air bag unit is located on steering wheel hub. Remove Torx
head retaining screws on rear of steering wheel. See Fig. 2. Lift air
bag unit from steering wheel, and tilt air bag unit downward.
Disconnect wiring connector from air bag unit.Fig. 2: Removing Air Bag Unit
Courtesy of Volkswagen United States, Inc.
Installation
To install, reverse removal procedure. Tighten air bag unit
retaining screws to specification. See TORQUE SPECIFICATIONS table.
Reactivate air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM.
Check air bag indicator lights to ensure system is functioning
properly. See SYSTEM OPERATION CHECK.
SPIRAL SPRING REMOVAL & INSTALLATION
Removal
1) Before proceeding, follow air bag service precautions. See
SERVICE PRECAUTIONS. Disable air bag system. See DISABLING &
ACTIVATING AIR BAG SYSTEM.
2) Remove air bag unit. See AIR BAG UNIT. Remove steering
wheel. See STEERING WHEEL. Remove knee bar panel and steering column
lower trim. Disconnect 2-pin wiring connector (Green/Black and
Green/Red wires) at base of steering column. Remove 3 spiral spring
retaining screws, and remove spiral spring. See Fig. 3.

STEERING COLUMN SWITCHES
Article Text (p. 4)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:51PMFig. 3: Removing Spiral Spring Assembly
Courtesy of Volkswagen United States, Inc.
Installation
1) To install spiral spring assembly, reverse removal
procedure. NEW spiral spring assemblies have a locking tab which locks
assembly in its centered position. Locking tab must be removed before
installing new spring assembly.
2) If a spiral spring assembly is reinstalled, it must be
centered. To center, turn spring assembly 4 turns from stop, in either
direction.
3) Reactivate air bag system. See DISABLING & ACTIVATING AIR
BAG SYSTEM. Check air bag indicator lights to ensure system is
functioning properly. See SYSTEM OPERATION CHECK.
STEERING WHEEL REMOVAL & INSTALLATION
Removal (Cabriolet)
1) Before proceeding, follow air bag service precautions. See
SERVICE PRECAUTIONS. Disable air bag system. See DISABLING &
ACTIVATING AIR BAG SYSTEM.
2) Turn front wheels to straight-ahead position. Remove air
bag unit. See AIR BAG UNIT under REMOVAL & INSTALLATION. Remove
steering wheel nut and spring washer. Mark steering wheel and shaft
for reassembly reference. Remove steering wheel.
Installation
To install, reverse removal procedure. Tighten steering wheel
nut to specification. See TORQUE SPECIFICATIONS table. Reactivate air
bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM. Check air bag
indicator lights to ensure system is functioning properly. See SYSTEM
OPERATION CHECK.
STEERING WHEEL & HORN PAD REMOVAL & INSTALLATION

STEERING COLUMN SWITCHES
Article Text (p. 6)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:51PMFig. 5: Removing Steering Wheel (Typical)
Courtesy of Volkswagen United States, Inc.
Installation
1) Coat slip ring contact surfaces with a light electrical
grease. Assemble horn button assembly (if disassembled). Ensure wheels
are in a straight-ahead position.
2) Aligning marks made during removal, place slip ring,
springs, canceling cams, steering wheel, washer and steering wheel
retaining nut on shaft.
3) Tighten steering wheel nut to specification. See TORQUE
SPECIFICATIONS table. To complete installation, reverse removal
procedure.
COMBINATION SWITCH REMOVAL & INSTALLATION
Removal
Remove steering wheel. Remove upper and lower steering column
covers. Disconnect combination switch harness connectors. Remove snap
ring and washer from steering shaft (if equipped). Remove combination
switch attaching screws. Remove combination switch.
Installation
To install, reverse removal procedure. Ensure all electrical
connections are tight. Check canceling operation of turn signal
switch.
STEERING LOCK & IGNITION SWITCH REMOVAL & INSTALLATION
Removal
1) Remove steering wheel, upper and lower steering column
covers and combination switch. Disconnect ignition switch harness
connectors.
2) Remove clamping washers, spring and contact ring from
steering column. Remove steering lock housing mounting bolt. Remove
steering lock housing from steering column.
Installation
1) To install, reverse removal procedure. Slide steering lock
housing onto steering column. Install contact ring, spring and

STEERING COLUMN SWITCHES
Article Text (p. 7)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:51PM
clamping washers onto steering column. Ensure proper operation of
steering lock and ignition switch.
NOTE: On Corrado, pull steering column upward from steering column
tube as far as possible to ensure proper column position.
2) Install combination switch, upper and lower steering
column covers and steering wheel. Tighten steering wheel nut to
specification. See TORQUE SPECIFICATIONS table.
LOCK CYLINDER REMOVAL & INSTALLATION
Removal
1) Remove steering wheel. Remove combination switch and upper
and lower steering wheel covers. Mark steering lock housing at
intersection of "A" and "B" for hole. See Fig. 6. "A"=12 mm; "B"=10
mm.
2) Drill 3 mm hole into steering lock housing at mark until
lock cylinder stop spring is visible. Hole depth will be approximately
3 mm. Compress stop spring with punch and pull lock cylinder out.Fig. 6: Drilling Steering Lock Housing
Courtesy of Volkswagen United States, Inc.
Installation
1) Insert lock cylinder into steering lock housing. Insert
key into lock cylinder. Push lock cylinder fully into housing while
gently turning key.
2) Install combination switch and upper and lower steering
column covers. Install steering wheel and nut. Tighten steering wheel
nut to specification. See TORQUE SPECIFICATIONS table.

STEERING COLUMN SWITCHES
Article Text (p. 8)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:51PM
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Ft. Lbs. (N.m)
Steering Wheel Nut ......................................... 30 (40)
INCH Lbs. (N.m)
Air Bag Unit-To-Steering Wheel Screws ...................... 89 (10)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE

STEERING SYSTEM - POWER
Article Text (p. 3)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:51PM
3) If pump pressure is not within specification, replace
pump.
STEERING WHEEL TURNING FORCE
Except Vanagon
Remove steering gear. See POWER RACK & PINION under REMOVAL &
INSTALLATION. Loosen lock nut. Turn adjuster bolt until pinion shaft
can be turned by hand without binding. Hold adjuster bolt in position
while tightening lock nut.
Vanagon
If steering effort is too high, check steering shaft,
steering linkage, "U" joints, and ball joints for binding. If all are
okay, replace steering gear.
REMOVAL & INSTALLATION
POWER STEERING PUMP
Removal
Remove alternator and pump belts. Disconnect hydraulic lines
from pump. Cap lines to prevent contamination. Remove bracket bolts.
Remove pump. See Fig. 2.
Installation
To install, reverse removal procedure. Adjust belt tension.
See POWER STEERING PUMP BELT under ADJUSTMENTS. Tighten nuts and bolts
to specification. See TORQUE SPECIFICATIONS table at end of article.
Fill and bleed hydraulic system. See HYDRAULIC SYSTEM BLEEDING. Start
engine and check for leaks.Fig. 2: Identifying Typical Power Steering Pump Components
Courtesy of Volkswagen United States, Inc.
POWER RACK & PINION
NOTE: Refer to illustration for exploded view of power rack and

STEERING SYSTEM - POWER
Article Text (p. 4)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:51PM
pinion components. See Fig. 1.
Removal (Cabriolet)
1) Remove pressure line from pump. Drain fluid from pump and
line. Disconnect tie rod ends from steering knuckles. Remove
transmission mount and bracket. Remove exhaust manifold.
2) Remove hydraulic lines from steering gear. Plug openings.
Remove shift linkage from steering gear (if equipped). Remove ground
wire. Disconnect pinion shaft at "U" joint. Remove retaining bolts and
steering gear.
Removal (Corrado)
1) Disconnect return line from pump. Drain fluid from pump
and line. Disconnect tie rod ends from steering knuckles.
2) Remove lock bolt at "U" joint. Remove steering gear
retaining bolts. Disconnect hydraulic lines at steering gear. Plug
openings.
3) Support engine and transmission. Remove subframe bolts.
Remove steering gear.
Removal (Golf, GTI & Jetta)
1) Disconnect return line from pump. Drain fluid from pump
and line. Disconnect tie rod ends from steering knuckles.
2) Remove shift linkage from steering gear (if equipped).
Disconnect pinion shaft at "U" joint. Disconnect hydraulic lines from
steering gear. Plug openings. Remove retaining bolts.
3) Support engine and transmission with Engine Support (10-
222A). Remove left transmission mount bolts. Loosen right transmission
mount bolts. Remove steering gear.
Removal (Passat)
1) Disconnect return line from pump. Drain fluid from pump
and line. Disconnect tie rod ends from steering knuckles.
2) Support engine and transmission with Engine Support (10-
222A and 10-222A/1). Remove steering gear boot. Remove transmission
mount bolts. Lower engine/transmission sufficiently to separate
steering shaft halves.
3) Disconnect hydraulic lines from steering gear. Plug
openings. Remove retaining nuts and steering gear.
Removal (Vanagon)
1) Removal and installation information is not available from
manufacturer.
Installation (All Models)
Reverse removal procedure to install. Tighten nuts and bolts
to specification. See TORQUE SPECIFICATIONS table at end of article.
Fill and bleed hydraulic system. See HYDRAULIC SYSTEM BLEEDING. Check
wheel alignment. See appropriate WHEEL ALIGNMENT SPECIFICATIONS &
PROCEDURES article in the WHEEL ALIGNMENT section:
* WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES - (1990 - All

STEERING SYSTEM - POWER
Article Text (p. 5)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:51PM
models except Corrado & Passat)
* WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES - (1990 -
Corrado & Passat)
* WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES - 1991
* WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES - 1992
OVERHAUL
Manufacturer recommends that power steering pump and steering
gear be replaced, rather than be repaired.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Ft. Lbs. (N.m)
End Housing Bolt ................................. 37 (50)
Power Steering Pump Bolt ......................... 18 (25)
Pressure-Flow Limiting Valve Cap ................. 42 (57)
Pressure Line Fitting ............................ 29 (39)
Return Line Fitting
On Pump ........................................ 29 (39)
On Valve Housing ............................... 22 (30)
Steering Gear Adjuster Lock Nut ..................... (1)
Steering Gear Retaining Bolt ...................... 22 (30
Subframe Bolt
Long .......................................... 96 (130)
Short .......................................... 59 (80)
Tie Rod-to-Steering Arm .......................... 32 (44)
Valve Housing Bolt ............................... 15 (20)
(1) - Not specified by manufacturer.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE

SUSPENSION - FRONT
Article Text (p. 2)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:51PMFig. 2: Exploded View Of Front Suspension
ADJUSTMENTS & INSPECTION
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
NOTE: See SPECIFICATIONS & PROCEDURES article in the WHEEL
ALIGNMENT Section.
WHEEL BEARING
No adjustment is required.
BALL JOINT CHECKING
Raise and support vehicle. Inspect ball joints for excessive
play and damaged rubber boots. Maximum tolerance for ball joint play
not available from manufacturer.

SUSPENSION - FRONT
Article Text (p. 4)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:51PM
Installation
Slide new ball joint into slot in control arm. Install and
tighten ball joint retaining bolts. Install lower control arm to
subframe. Install ball joint into wheel bearing housing. To complete
installation, reverse removal procedure. Tighten control arm bolts
with vehicle on ground. Tighten all bolts and nuts to specification.
See TORQUE SPECIFICATIONS TABLE at end of article. Check wheel
alignment. See SPECIFICATIONS & PROCEDURES article in the WHEEL
ALIGNMENT Section.
STRUT ASSEMBLY
Removal
1) Raise and support vehicle. Remove wheel assembly. Remove
and support caliper assembly out of work area. Remove bolts which
retain strut to wheel bearing housing. Note top bolt is used to adjust
front wheel camber.
2) Support front suspension arm and related components. Pry
suspension strut from wheel bearing housing. Working inside engine
compartment, remove upper strut retaining nuts. Remove strut.
Installation
To install, reverse removal procedure. Tighten bolts and nuts
to specification. See TORQUE SPECIFICATIONS TABLE at end of article.
Check wheel alignment. See SPECIFICATIONS & PROCEDURES article in the
WHEEL ALIGNMENT Section.
FRONT SUSPENSION ASSEMBLY
Removal
1) Raise vehicle and support at center with safety stands.
Disconnect brake line and plug openings. Leave flex line in place.
Remove stabilizer link rod nut, bushings and washers.
2) Remove tie rod nut. Separate tie rod from wheel bearing
housing. Remove bolts retaining inner portion of constant velocity
joint to transaxle drive flange.
3) Remove lower control arm front pivot bolt. Remove bolts
retaining "U" shaped bracket holding control arm rear pivot.
NOTE: On vehicles with automatic transmission, engine may have to
be lifted slightly to gain access to pivot bolts.
4) Support suspension assembly being removed. Remove upper
strut retaining nuts. Remove suspension assembly from vehicle.
Installation
To install, reverse removal procedure. Make sure convex side
of thrust washer faces pivot bolt head. Tighten bolts and nuts to
specification. Check wheel alignment.See SPECIFICATIONS & PROCEDURES
article in the WHEEL ALIGNMENT Section.
WHEEL BEARING