1990 VOLKSWAGEN CORRADO air bleeding

ANTI-LOCK BRAKE SAFETY PRECAUTIONS
Article Text
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:42PM
ARTICLE BEGINNING
GENERAL INFORMATION
Anti-Lock Brake Safety Precautions
* PLEASE READ THIS FIRST *
This article is intended for general information purposes
only. This information may not apply to all makes and models. If
vehicle is equipped with Anti-Lock Brake System (ABS), refer to
appropriate ANTI-LOCK BRAKE SYSTEM article in the BRAKES section for
description, operation, depressurizing, testing, system bleeding,
trouble shooting and servicing of specific system.
WARNING: Failure to depressurize ABS could lead to physical injury.
ANTI-LOCK BRAKE SAFETY PRECAUTIONS
WARNING: Failure to depressurize ABS could lead to physical injury.
* NEVER open a bleeder valve or loosen a hydraulic line
while ABS is pressurized.
* NEVER disconnect or reconnect any electrical connectors
while ignition is on. Damage to ABS control unit may result.
* DO NOT attempt to bleed hyudarulic system without first
referring to the appropriate ANTI-LOCK BRAKE SYSTEM article
in the BRAKES section.
* Only use specially designed brake hoses/lines on ABS equipped
vehicles.
* DO NOT tap on speed sensor components (sensor, sensor rings).
Sensor rings must be pressed into hubs, NOT hammered into
hubs. Striking these components can cause demagnetization or
a loss of polarization, affecting the accuracy of the speed
signal returning to the ABS control unit.
* DO NOT mix tire sizes. Increasing the width, as long as tires
remain close to the original diameter, is acceptable. Rolling
diameter must be identical for all 4 tires. Some
manufacturers recommend tires of the same brand, style and
type. Failure to follow this precaution may cause inaccurate
wheel speed readings.
* DO NOT contaminate speed sensor components with grease. Only
use recommended coating, when system calls for an
anti-corrosion coating.
* When speed sensor components have been removed, ALWAYS check
sensor-to-ring air gaps when applicable. These specifications
can be found in each appropriate article.
* ONLY use rocommended brake fluids. DO NOT use silicone brake
fluids in an ABS equipped vehicle.
* When instlling transmittion devices (CB's, telephones, etc.)
on ABS equipped vehicles, DO NOT locate the antenna near the
ABS control unit (or any control unit).

ANTI-LOCK BRAKE SYSTEM
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 09:42PM
style and type. Failure to follow this precaution may cause
inaccurate wheel speed readings.
* DO NOT contaminate speed sensor components with grease. Only
use recommended anti-corrosion coating.
* When speed sensor components have been removed, ALWAYS check
sensor-to-ring gap when applicable. These specifications can
be found in WHEEL SPEED SENSOR under ADJUSTMENTS.
* ONLY use recommended brake fluids. DO NOT use silicone brake
fluids in an ABS equipped vehicle.
* When installing transmitting devices (CB's, telephones, ect.)
on ABS equipped vehicles, DO NOT locate antenna near the ABS
control unit or any control unit.
* Disconnect all on-board computers when using electric welding
equipment.
* DO NOT expose the ABS control unit to prolonged periods of
high heat (185øF/85øC for 2 hours is generally considered a
maximum limit).
CAUTION: The ABS system is under extremely high pressure.
Depressurize the brake system before loosening or removing
any hydraulic component.
DEPRESSURIZING BRAKE SYSTEM
Turn ignition off. Depress and release brake pedal 25-35
times, or until there is a noticeable increase in the effort to
depress the brake pedal. Do not turn ignition on until all hydraulic
lines and components are fully tighten.
BLEEDING BRAKE SYSTEM
FRONT BRAKES
Depressurize brake system. See DEPRESSURIZING BRAKE SYSTEM.
Connect a container with hose to left front bleeder screw. Have
assistant depress and release brake pedal a few times. Holding brake
pedal down, open bleeder screw and allow fluid to enter container.
Close bleeder screw and then release brake pedal. Continue this method
until no air is present in fluid. Check master cylinder fluid level to
make sure it does not go below minimum level mark. Use same procedure
for right front brake.
REAR BRAKES
CAUTION: When bleeding rear brakes, accumulator pressure (about 3100
psi) is used to assist in procedure. Use eye protection
when performing this procedure. DO NOT allow pump to run
longer than 2 minutes. See ANTI-LOCK BRAKE SAFETY
PRECAUTIONS in this article.
Attach hose and container to right rear bleeder screw.
Position actuator lever on load-sensing pressure regulator toward rear

ANTI-LOCK BRAKE SYSTEM
Article Text (p. 11)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:42PM
REMOVAL & INSTALLATION
HYDRAULIC MODULATOR/PUMP
Removal & Installation
1) Depressurize brake system. See DEPRESSURIZING BRAKE
SYSTEM. Disconnect negative battery cable. Unplug all electrical
connectors from hydraulic modulator/pump. Identify and disconnect all
hydraulic lines from hydraulic modulator/pump. Plug all line openings.
2) From inside passenger compartment, remove push rod clevis
pin. Remove hydraulic modulator/pump retaining nuts. Remove hydraulic
modulator/pump. To install, reverse removal procedure. Tighten all
fittings to specification. See TORQUE SPECIFICATIONS TABLE at end of
article. Bleed brake system. See BLEEDING BRAKE SYSTEM.
WHEEL SPEED SENSORS
NOTE: To protect magnetic part of sensor, always leave new wheel
speed sensor in special packaging until ready for
installation.
Removal & Installation
Remove bolt retaining wheel speed sensor. Unplug connector.
Remove wheel speed sensor. To install, apply Lubricant (G-000-650) to
sensor. Install sensor, and tighten retaining bolt to 84 INCH lbs. (10
N.m).
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplications Ft. Lbs. (N.m)
Brake Lines-To-Hydraulic Modulator/Pump ............... 11 (15)
Hydraulic Modulator/Pump Retaining Nuts ............... 18 (25)
INCH Lbs. (N.m)
Wheel Sensor Retaining Bolt .......................... 84 (9.5)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ WIRING DIAGRAMS

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. 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

TROUBLE SHOOTING - BASIC PROCEDURES
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 09:52PM
Parallelism not to
specifications Reface or replace rotor
Wheel bearings not adjusted See SUSPENSION
Rear drums out-of-round Reface or replace drums
Disc pad reversed, steel
against rotor Remove and reinstall
padÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄExcessive Pedal
Effort Malfunctioning power unit See POWER BRAKES or
BRAKE SYSTEM
Partial system failure Check fluid and pipes
Worn disc pad or lining Replace pad or lining
Caliper piston stuck or
sluggish See DISC BRAKES or
BRAKE SYSTEM
Master cylinder piston
stuck See MASTER CYLINDERS
or BRAKE SYSTEM
Brake fade due to incorrect
pads for linings Replace pads or linings
Linings or pads glazed Replace pads or linings
Worn drums Reface or replace drums
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄExcessive Pedal
Travel Partial brake system failure Check fluid and pipes
Insufficient fluid in
master cylinder See MASTER CYLINDERS or
BRAKE SYSTEM
Air trapped in system See BRAKE BLEEDING or
BRAKE SYSTEM
Rear brakes not adjusted See Adjustments in DRUM
BRAKES or BRAKE SYSTEM
Bent shoe or lining See DRUM BRAKES or
BRAKE SYSTEM
Plugged master cylinder cap See MASTER CYLINDERS
or BRAKE SYSTEM