1993 VOLKSWAGEN CORRADO Repair Manual

STEERING GEAR - POWER RACK & PINION
Article Text (p. 2)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:23PMFig. 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 INSPECTION
Ensure fluid level is okay. Check service belt condition and
adjustment. Ensure hoses are not kinked or leaking.
PUMP PRESSURE TEST
Install Pressure Gauge (US 1074 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. Pressure
should be within specification. See POWER STEERING SYSTEM PRESSURE
table. If pump pressure is not within specification, replace pump.
POWER STEERING SYSTEM PRESSURE TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Pressure
Model psi (bar)
Corrado ................................. 1102-1189 (76-82)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ STEERING GEAR INSPECTION

STEERING GEAR - POWER RACK & PINION
Article Text (p. 3)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:23PM
Remove rack and pinion assembly. 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.
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
pinion components. See Fig. 1.
Removal
1) Disconnect return line from pump. Drain fluid from pump
and line. Disconnect tie rod ends from steering knuckles. Remove lock
bolt at "U" joint.
2) Remove steering gear retaining bolts. Disconnect hydraulic
lines at steering gear. Plug openings. Support engine and
transmission. Remove subframe bolts. Remove steering gear.

STEERING GEAR - POWER RACK & PINION
Article Text (p. 4)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:23PM
Installation
To install, reverse removal procedure. 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 WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
article in the WHEEL ALIGNMENT section.
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 Retaining Bolt ..................... 24 (33)
Subframe Bolt
Long .......................................... 96 (130)
Short .......................................... 59 (80)
Tie Rod Lock Nut ................................. 42 (55)
Tie Rod-To-Steering Arm .......................... 32 (44)
Valve Housing Bolt ............................... 15 (20)
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄEND OF ARTICLE

SUN ROOF - POWER
Article Text
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:23PM
ARTICLE BEGINNING
1993 ACCESSORIES & EQUIPMENT
Volkswagen Power Sun Roof
Volkswagen; Corrado SLC, EuroVan, Golf, GTI, Jetta, Passat
DESCRIPTION & OPERATION
The power sun roof operates at all times when the ignition is
in the on position. Power sun roof will operate after the ignition is
turned off until driver's door is opened. Power sun roof can also be
closed by inserting key in door lock and holding in the locked
position. If power system fails, sun roof can be operated manually by
removing control panel and rotating crank.
ADJUSTMENTS
NOTE: Adjustment information for EuroVan is not available.
PARALLEL ALIGNMENT
Corrado SLC, Golf, GTI, Jetta & Passat
1) Obtain radio code. Disconnect negative battery cable.
Using Headliner Trim Remover (3195), disengage headliner trim frame
from guide rails and push toward rear as far as possible. See Fig. 5
or 7.
2) Pry off interior light. Remove sun roof cable drive cover.
Remove cable drive mounting screws. Lower pinion drive until drive
pinion no longer meshes with cables.
3) Move rear guides with cables to rear. Ensure pivots
position is correct. See Fig. 1. Engage locking levers into guide
rails. Drive cable should be in the closed position.
4) Clean cable drive mounting screws and coat threads with
locking compound. Install cable guide and interior light. Install
headliner trim frame onto guides. Reconnect negative battery cable.Fig. 1: Aligning Guide Rail Pivot Position
(Corrado SLC, Golf, GTI, Jetta & Passat)
Courtesy of Volkswagen United States, Inc.
SUN ROOF HEIGHT ADJUSTMENT

SUN ROOF - POWER
Article Text (p. 2)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:23PM
Corrado SLC, Golf, GTI, Jetta & Passat
Loosen adjustment screws. Adjust height by positioning sun
roof panel at .01" (1 mm). See Fig. 2. Tighten adjustment screws to 48
Inch lbs (4.5 Nm).Fig. 2: Adjusting Sun Roof Panel
Courtesy of Volkswagen United States, Inc.
MAINTENANCE
DRAIN TUBES
Front drain tubes are routed through A pillars and discharge above
front door hinge. Rear drain tubes are routed through D pillars and
discharge behind rear wheel housing. Clean rear drain tubes through
sun roof opening.
NOTE: Compressed air can be used to clean drain tubes
TESTING
NOTE: Test information is not available from manufacturer.
REMOVAL & INSTALLATION
CARRIER UNIT
Removal & Installation (Golf, GTI & Jetta)
1) Obtain radio code. Disconnect negative battery cable.
Remove sliding glass panel. Remove molding from headliner cut-out.
Remove electric drive motor cover.

SUN ROOF - POWER
Article Text (p. 3)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:23PM
2) Remove pillar trim and electric drive motor. Remove
carrier unit attaching bolts. Remove carrier unit. See Fig. 7. To
install, reverse removal procedure. Push sliding headliner to rear
until both springs engage.
SLIDING SUN ROOF PANEL
Removal & Installation (Corrado SLC & Passat)
1) Slide headliner to rear. Tilt sun roof panel up. Install
Sun Roof Remover (3195) into sun roof opening. See Fig. 3.
2) Pull sliding headliner and tilting frame down until sun
roof remover engages headliner trim frame. See Fig. 5. Disengage
headliner trim frame from guide rails by hitting sun roof remover
toward rear.
3) Push back headliner trim frame until sun roof remover
contacts edge of roof cutout. Remove adjusting plate Torx screws.
Remove adjusting plate. Pull sun roof panel upward to remove. To
install, reverse removal procedure.Fig. 3: Installing Sun Roof Remover Into Sun Roof Opening
Courtesy of Volkswagen United States, Inc.
Removal & Installation (EuroVan)
1) Ensure sun roof panel is closed. Turn rotary handle screw
about 1/4 turn until sun roof panel disengages from latch. See Fig. 4.
2) Turn rotary handle clockwise until sun roof is raised.
Ensure sun roof panel does not engage latch. Press lock lever upward.
Unlatch sun roof and remove from brackets. See Fig. 6. To install,
reverse removal procedure.

SUN ROOF - POWER
Article Text (p. 4)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:23PMFig. 4: Identifying Rotary Handle & Locking Lever
Courtesy of Volkswagen United States, Inc.
Removal & Installation (Golf, GTI & Jetta)
1) Slide headliner to rear. Tilt glass panel open. Unclip
trim frame. Slide trim frame to rear. See Fig. 7.
2) Remove adjusting plate Torx screws. Remove adjusting
plate. Pull glass panel upward to remove. To install, reverse removal
procedure.
SLIDING HEADLINER
Removal & Installation (Golf, GTI & Jetta)
1) Remove sliding glass panel and move trim frame to rear.
Using a small screwdriver, pry guide feet out of carrier guide by
prying on one side while pressing sliding headliner into opposite
guide channel.
2) Release spring and pull sliding headliner out of roof cut-
out. See Fig. 7. To install, reverse removal procedure. Push sliding
headliner to rear until both springs engage.

SUN ROOF - POWER
Article Text (p. 5)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 09:24PMFig. 5: Exploded View Of Power Sun Roof Assembly
(Corrado SLC & Passat)
Courtesy of Volkswagen United States, Inc.