1990 VOLKSWAGEN CORRADO Repair Manual

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

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