VOLKSWAGEN CORRADO 1990 Repair Manual

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
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 SUSPENSION
Volkswagen Front
1990-92 Passat
1991-92 Cabriolet, Corrado, Golf, GTI, Jetta
DESCRIPTION
FWD suspension system has MacPherson struts. Wheel bearing
housings are supported by lower control arms and vertically mounted
strut assemblies. See Fig. 1 or 2.Fig. 1: Exploded View of Front Suspension (Typical)

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. 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
REMOVAL & INSTALLATION
HUB & KNUCKLE ASSEMBLY
Use exploded view illustration when removing or installing
hub and knuckle assembly. See Fig. 1 or 2.
LOWER CONTROL ARM & BALL JOINT
Removal
1) Raise and support vehicle. Remove bolt retaining ball
joint at wheel bearing housing. Force ball joint from of housing.
Leave control arm hanging in mounts at subframe.
2) If control arm is not to be removed and ball joint is
riveted to control arm, drill out ball joint rivets using a 9/32" (7
mm) drill. After drilling rivets, chisel off rivet heads if necessary.
Remove ball joint. See Fig. 3.Fig. 3: Installing Lower Ball Joint
Courtesy of Volkswagen United States, Inc.
3) If control arm is to be removed, remove stabilizer bar
link rod nut, washers, and bushings. Remove pivot bolt and "U" bracket
housing inner pivot pin. Slide out control arm.
NOTE: On vehicles with automatic transmission, engine may have to
be lifted slightly to gain access to pivot bolts.
Inspection
Check lower control arm bushings. Replace bushings if
necessary. To replace bushings, press out worn bushing. Select new
bushing and press into position. Make sure bushing does not twist when
seating into place.

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

SUSPENSION - FRONT
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
NOTE: Wheel bearing is destroyed when pressed out of housing. When
either wheel hub or bearing has been removed from housing, a
new bearing must be installed.
Removal
1) Remove axle shaft nut. Raise and support vehicle with
safety stands. Allow suspension to hang free. Remove wheel assembly.
Remove brake caliper attaching bolts. Remove caliper and hang out of
work area. Remove brake disc retaining screw and remove disc.
2) Remove tie rod ball joint from wheel bearing housing.
Remove nut and clamp bolt from control arm ball joint. Remove control
arm ball joint from wheel bearing housing and remove housing.
3) Remove 2 circlips retaining bearing in hub. Using Hub
Remover (VW 295a), press wheel hub from bearing housing. Using a
bearing puller, remove wheel bearing inner race from hub assembly.
Using Bearing Remover (VW 433), press wheel bearing from outboard end
of bearing housing.
Installation
1) Press new bearing race onto hub. Using Bearing & Hub
Installer (VW 472/1), press new bearing into bearing housing from
outboard side. Using same adapter, press wheel hub into bearing
housing. Apply a small bead of locking compound to axle splines before
installing into hub.
2) To complete installation, reverse removal procedure.
Always replace self-locking axle shaft nut. 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.
NOTE: When installing hub, ensure press adapter contacts inner
bearing race only.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Ft. Lbs. (N.m)
Axle Nut ............................................ 170 (230)
Axle Shaft-To-Transaxle Bolt .......................... 32 (43)
Ball Joint Clamp Bolt ................................. 37 (50)
Ball Joint-To-Control Arm Bolt ........................ 18 (24)
Caliper Pin Bolt ...................................... 18 (24)
Control Arm Pivot Bolt
Cabriolet ........................................... 50 (68)
All Others ......................................... 96 (130)
Control Arm-To-Subframe Rear Bushing Bolt ............ 96 (130)
Strut Piston Rod Nut
Cabriolet ........................................... 50 (68)
All Others .......................................... 44 (60)

SUSPENSION - FRONT
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 09:51PM
Suspension Strut-To-Wheel Bearing Housing Bolt ........ 59 (80)
Tie Rod Castle Nut .................................... 26 (35)
Wheel Lug Bolt ....................................... 81 (110)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE

SUSPENSION - REAR
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 SUSPENSION
Volkswagen Rear
Cabriolet, Corrado, Fox,
Golf, GTI, Jetta, Passat
DESCRIPTION
Rear suspension is link type with MacPherson suspension
struts. Suspension uses control arms and axle beam for stabilization.
Control arms and axle beam are combined as one unit. Brake drums or
discs rotate on stub axles bolted to control arms. See Fig. 1.Fig. 1: Identifying Rear Suspension Components (Typical)
Courtesy of Volkswagen United States, Inc.
ADJUSTMENTS & INSPECTION
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
NOTE: See SPECIFICATIONS & PROCEDURES article in the WHEEL
ALIGNMENT Section.
WHEEL BEARING
Tighten hub nut to 7.5 ft. lbs. (10 N.m) while rotating brake

SUSPENSION - REAR
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
disc or drum by hand. Insert tip of screwdriver between thrust washer
and hub. Adjustment is correct when light finger pressure against
screwdriver moves thrust washer. Turn hub nut to adjust. Install NEW
cotter pin.
REMOVAL & INSTALLATION
AXLE BEAM PIVOT BUSHING
NOTE: The following procedure is for replacing bushing with axle
beam installed in vehicle.
Removal
This procedure is for replacing bushing with axle beam
installed in vehicle. Raise and support vehicle. With no pressure on
beam, remove nuts which retain axle beam to body. Tap out pivot bolt.
Using Bushing Remover (VW 3111), press out bushing. Press new bushing
into place.
Installation
1) Loosely install mounting pad onto axle beam. Install
bushing to a depth of 2.42-2.44" (61.5-62.0 mm). Concave washer and
bolt head must face toward outside of vehicle. Bolt head must recess
into washer.
2) Using Mounting Bracket Aligner (VW 261 or 3021), align
mount. See Fig. 2. With vehicle on ground, tighten pivot bolt nut to
specification.Fig. 2: Aligning Axle Beam Mounting Pad
Courtesy of Volkswagen United States, Inc.
STRUT ASSEMBLY