VOLKSWAGEN CORRADO 1990 Repair Manual

STEERING COLUMN SWITCHES
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 09:51PM
If control light does not glow when ignition is turned to ON
position or does not go out after 5-8 seconds, a fault probably exists
in system. If a fault occurs while ignition is on, it is stored in
fault memory. Warning light will then glow and air bag system will be
switched off. If warning light glows or flickers while driving, air
bag system should be tested. See AIR BAG article in the
ACCESSORIES/SAFETY EQUIPMENT Section.Fig. 1: Locating Air Bag Warning & Control Lights
Courtesy of Volkswagen United States, Inc.
DISABLING & ACTIVATING AIR BAG SYSTEM
WARNING: Wait about 20 minutes after deactivating air bag system
before servicing. Air bag system voltage is maintained for
about 20 minutes after system is deactivated. Servicing
system before 20 minutes may cause accidental air bag
deployment and possible personal injury.
To disable air bag system, disconnect negative battery cable
and wait 20 minutes before working on vehicle. To activate system,
reconnect negative battery cable. Perform a system operational check
to ensure proper system operation. See SYSTEM OPERATION CHECK.
ADJUSTMENTS
AIR BAG SPIRAL SPRING
To center spiral spring assembly, turn spring assembly 4
turns from stop in either direction.
AIR BAG UNIT REMOVAL & INSTALLATION
WARNING: On Cabriolet equipped with a driver-side air bag, use
extreme caution while servicing steering column. Failure to

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. 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
Removal (Except Cabriolet)
1) Disconnect negative battery cable. Remove screws attaching
horn button assembly/center pad to steering wheel from behind steering
wheel (if equipped).
2) Pull horn button assembly/center pad from steering wheel.
Use a cloth covered screwdriver to pry off horn button assembly/center
pad (if necessary). Disassemble horn button assembly (if necessary).
3) Place springs, contacts, horn or cruise control harness
connectors and screws in order for reassembly reference. See Fig. 4.
Place wheels in straight-ahead position.
4) Remove steering wheel retaining nut and washer. Mark
steering wheel and shaft for reassembly reference. Using a steering
wheel puller, remove steering wheel. See Fig. 5.
5) Place steering wheel, cruise control set/resume switch
(if equipped), canceling cams, springs and slip rings in order for
reassembly reference.Fig. 4: Typical Steering Wheel Components (Without Air Bag - Fox
Shown; Others Are Similar)
Courtesy of Volkswagen United States, Inc.

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
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:51PM
ARTICLE BEGINNING
1990-92 STEERING
Volkswagen - Power Rack & Pinion
1990-92 Passat
1991-92 Cabriolet, Corrado, Golf, GTI, Jetta, Vanagon
DESCRIPTION & OPERATION
System consists of a vane pump, rack and pinion steering
gear, and an oil reservoir. Vane pump draws fluid from reservoir and
supplies it to flow control valve. Control valve directs fluid to
appropriate side of rack piston.
LUBRICATION
CAPACITY
Fluid capacity is approximately 1 qt. (.95L).
FLUID TYPE
On all models, the recommended fluid type is V.W. Hydraulic
Oil (G 002 000).
FLUID LEVEL CHECK
Remove reservoir cover. Start engine and let idle. Fluid
level should be between MIN and MAX marks on reservoir.
HYDRAULIC SYSTEM BLEEDING
1) Start engine and let idle. Ensure fluid is at proper
level. Turn steering wheel from lock to lock several times quickly.
2) Continue until fluid level remains at reservoir mark.
Ensure no bubbles appear in reservoir when steering wheel is turned.
Shut off engine. Ensure oil level does not rise more than 3/8" (10
mm).

STEERING SYSTEM - POWER
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. 1: Identifying Typical Power Rack & Pinion Components
Courtesy of Volkswagen United States, Inc.
ADJUSTMENTS
POWER STEERING PUMP BELT
Loosen nuts on pump mounting bracket. Turn adjuster bolt
until belt deflection is 3/8" (10 mm) at center of belt. Tighten nuts
to specification.
TESTING
HYDRAULIC SYSTEM PRESSURE TEST
1) Install Pressure Gauge (US1074 B) between pressure hose
and pressure line at valve housing. Open pressure gauge valve. Run
engine at idle. Turn steering wheel from lock to lock several times.
2) On Vanagon, pressure should be 1670-1750 psi (117-123
kg/cmý). On all others, pressure should be 1100-1200 psi (78-84
kg/cm
ý). If pressure is not within limits, see PUMP PRESSURE TEST.
3) If pump pressure is within specification, but system
pressure is low, replace steering gear.
PUMP PRESSURE TEST
1) Install Pressure Gauge (US1074 B) between pressure hose
and pressure line of valve housing. Start engine and let idle. Close
valve. Leave valve closed for no longer than 5 seconds. On Vanagon,
pressure should be 1670-1750 psi (117-123 kg/cm
ý). On all others,
pressure should be 1100-1200 psi (78-84 kg/cm
ý).
2) On all vehicles except Vanagon, go to step 3). On Vanagon,
if pressure is not to specification, inspect limiting valve and
housing bores and piston for obstructions. Ensure piston moves freely
in housing. Install new valve if necessary.

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