1990 VOLKSWAGEN CORRADO check oil

A/C COMPRESSOR SERVICING
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 09:41PM
recovery/recycling equipment before loosening any fittings.
DISCONNECTING LINES & FITTINGS TEST
After system is discharged, carefully clean area around all
fittings to be opened. Always use 2 wrenches when tightening or
loosening fittings to avoid twisting or distorting lines. Cap or plug
all openings as soon as lines are removed. Do not remove caps until
immediately before connections are made. This will keep entry of air
and moisture to a minimum.
CONNECTING LINES AND FITTINGS
A new gasket or "O" ring should be used in all instances when
connecting lines or fittings. Dip "O" ring in new refrigerant oil and
ensure it is not twisted during installation. Always use 2 wrenches to
prevent damage to lines and fittings.
PLACING SYSTEM IN OPERATION
After component service or replacement has been completed and
all connections have been made, evacuate system thoroughly with a
vacuum pump. Charge system with proper amount of refrigerant and
perform a leak test. See REFRIGERANT OIL & R-12 SPECIFICATIONS chart
in this section for system capacities. Be sure to check all fittings
that have been opened. After system has been leak tested, make a
system performance check.
NOTE: Air conditioning systems will not normally need addition of
refrigerant oil unless definite oil loss has occurred due to
ruptured lines, leaking compressor seals, compressor
overhaul or component replacement.
ATSUGI ROTARY VANE CLUTCH R & I
Removal
When replacing compressor clutch, be careful not to scratch
shaft or bend pulley. When removing center bolt, hold clutch disc with
Clutch Holder (KV99231010). Using Hub Puller (KV998VR001 &
KV99231010), remove clutch disc. When removing pulley, remove lock nut
with Hub Socket (KV99235160).
Installation
Wipe oil off clutch surface. Adjust disc pulley clearance to
.012-.024" (.3-.6 mm). Tighten center bolt to 80-104 INCH lbs. (9.1-
11.8 N.m). Tighten clutch lock nut to 22-29 ft. lbs. (29-39 N.m). See
Fig. 1.

A/C COMPRESSOR SERVICING
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 09:41PM
Seal Seat Remover/Installer (64 5 030), remove seal seat.
2) Using Seal Remover/Installer (64 5 040), remove shaft seal
by turning seal slightly clockwise to disengage tangs and pull out
shaft seal. Remove "O" ring seal.
3) Coat new "O" ring seal with refrigerant oil and install.
Coat new shaft seal with refrigerant oil and install shaft seal on
Seal Remover/Installer (64 5 040). Ensure alignment of shaft seal and
shaft machine surfaces. Insert shaft seal and turn slightly
counterclockwise to secure on shaft.
4) Using sleeve from Seal Seat Remover/Installer (64 5 030),
push seal seat into compressor and install circlip. Install shaft key
and clutch plate. Check compressor oil level before charging system.Fig. 2: Bosch 6-Cylinder Compressor Clutch
Courtesy of BMW of North America, Inc.
CALSONIC V5 CLUTCH R & I
NOTE: Compressor servicing information is not available from
manufacturer.
DIESEL KIKI ROTARY VANE CLUTCH R & I
Removal
1) Using Clutch Holder (KV99231010), hold clutch disc. Remove
center bolt retaining clutch assembly to shaft. Thread Hub Remover
(KV99232232) into bore of clutch hub. Hold hub remover with wrench and
thread center bolt inward until clutch disc is removed.
2) Remove clutch disc, collar and adjusting shims. Remove
snap ring and plate. Remove pulley and bearing assembly. If assembly
cannot be removed by hand, use a puller and adapter.
3) Be careful not to scratch shaft or bend pulley. Using an
impact driver, loosen 6 coil mounting screws. Remove key and clutch
coil. See Fig. 3.
Installation
1) Install key. Position coil assembly on compressor body. Be
sure that electrical terminals are installed in original position.

A/C COMPRESSOR SERVICING
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 09:41PM
Install and tighten coil mounting screws to 35-52 INCH lbs. (4-6 N.m).
2) Press pulley assembly onto neck of coil assembly using
Pulley Installer (KV99234160). Wipe oil thoroughly off clutch surface.
Select adjusting shims which give correct clearance between pulley and
clutch disc.
3) Using a plastic mallet, tap clutch disc in place on drive
shaft. Do not use excessive force with plastic mallet or press. Place
spring washer and center bolt onto drive shaft. Tighten center bolt to
drive clutch wheel onto drive shaft. Tighten center bolt to 11-13 ft.
lbs. (15-18 N.m).
4) Hold clutch with Clutch Holder (KV99231010). Check
clearance around entire outer edge of clutch disc. Clearance should be
.012-.024" (.3-.6 mm). If specified clearance is not obtained, replace
adjusting shims as required.
5) When replacing compressor clutch assembly, break-in
procedure must be performed. This is accomplished by engaging and
disengaging clutch 30 times.
DIESEL KIKI 6-CYL CLUTCH COIL R & I
Removal & Installation
Using clutch holder to prevent clutch disc rotation, remove
bolt. Using clutch holder and puller, remove clutch disc. Remove shims
from compressor drive shaft or clutch disc. Remove snap ring with
external snap ring pliers and then remove pulley. Using a gear puller,
remove pulley. Remove coil lead wire and 6 screws. Remove coil. To
install, reverse removal procedure. Adjust clutch disc-to-pulley
clearance to .010-.020" (.3-.6 mm). See Fig. 4.Fig. 3: Diesel Kiki Rotary Vane Compressor
Courtesy of Nissan Motor Co., U.S.A.

A/C COMPRESSOR SERVICING
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 09:41PM
DIESEL KIKI 6-CYL SHAFT SEAL R & I
Removal & Installation
1) Remove clutch coil assembly. Remove retainer and felt.
Discard retainer and felt. Using internal snap ring pliers, remove
seal seat snap ring. Remove seal seat and discard. Using a seal pick,
remove "O" ring from inside groove of shaft seal housing. Discard "O"
ring.
2) To remove shaft seal, push down and turn clockwise on seal
remover to engage tangs. Slowly draw seal from bore. Discard seal.
Check shaft and inside of compressor neck for dirt or foreign material
and ensure these areas are perfectly clean before installing new seal.
3) To install, reverse removal procedure. Coat "O" ring,
shaft seal, and seal seat with new refrigerant oil.Fig. 4: Diesel Kiki 6-Cylinder Compressor
Courtesy of Mitsubishi Motor Sales of America.
HARRISON R4 4-CYL CLUTCH R & I

A/C COMPRESSOR SERVICING
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 09:41PM
front cover. See Fig. 7.
Inspection
Check friction surfaces of clutch for damage due to excessive
heat, or excessive grooving due to slippage. Replace compressor
components as necessary. Oil or dirt on friction surfaces should be
cleaned with a solvent and a dry rag. Check coil for binding, shorted
or open leads.
Installation
1) Install coil assembly on compressor. Properly position
terminals. Using snap ring pliers, install snap ring. Using a plastic
mallet, drive pulley and bearing assembly onto neck of front cover.
Turn pulley, making sure that there is no noise and that rotation is
free. Ensure there is no pulley play.
2) Using snap ring pliers, install inner snap ring. Remove
all oil from clutch pulley. Fit key and clutch hub to shaft. Select
adjusting spacer which gives the correct clearance between pulley and
clutch hub.
3) Coat shaft nut with Loctite and install. Using a feeler
gauge, measure clutch hub-to-pulley clearance. Clearance should be .
020-.031" (.5-.8 mm). If specified clearance is not obtained, replace
adjusting spacer and readjust.
4) When replacing compressor clutch assembly, DO NOT forget
break-in operation. This is accomplished by engaging and disengaging
clutch 30 times.

A/C COMPRESSOR SERVICING
Article Text (p. 12)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PMFig. 7: Hitachi 6-Cylinder Compressor (5-Cylinder Similar)
Courtesy of Nissan Motor Co., U.S.A.
HITACHI 5 & 6-CYL SHAFT SEAL R & I
NOTE: Check compressor refrigerant oil level when replacing seals.
See COMPRESSOR REFRIGERANT OIL CHECKING article in this
section.
Removal
1) Drain oil from suction port, measure oil drained and
discard oil. Remove clutch hub, pulley, bearing assembly and coil
assembly. See HITACHI 5 & 6-CYLINDER CLUTCH R & I in this article.
2) Using snap ring pliers, remove retainer ring. Remove key
and plug low and high pressure openings of compressor with Plugs
(KV994C4531, KV994C4532 and KV994C4559).
3) Insert Adapter (KV994C1552) into hole in middle of blind

A/C COMPRESSOR SERVICING
Article Text (p. 16)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PM
To install, reverse removal procedure. Ensure snap rings are
installed with beveled side up. tighten shaft bolt to 10 ft. lbs.
(14 N.m). Ensure clutch clearance is .014-.026" (.36-66 mm). adjust
clearance by adding or subtracting shims as necessary.
NIPPONDENSO 6 & 10-CYL SHAFT SEAL R & I
NOTE: Check compressor refrigerant oil level when replacing seals.
See COMPRESSOR OIL CHECKING article in the AIR CONDITIONING &
HEAT section.
Removal
1) Hold clutch hub stationary and remove center nut. Screw
remover into center of hub. Turn center bolt to remove pressure plate.
2) Remove shims from shaft. Remove snap ring from inside of
pulley. Tap pulley off of shaft with plastic mallet. Be careful not to
distort pulley while removing.
3) Disconnect clutch coil wires from compressor housing.
remove snap ring inside coil and lift coil off compressor. Pry dust
seal out from around compressor shaft (if equipped).
4) Place shaft key remover on shaft and turn to remove key.
Remove drain plug (if equipped). Remove service valves-to-compressor
body bolts. Remove valves. Discard "O" rings. Drain oil out of
compressor.
5) Remove 6 through bolts from front head of compressor and
discard washers. Tap head loose from compressor; be careful not to
scratch sealing surfaces. remove snap ring (if equipped) from front
housing. Press seal plate out. Remove seal from shaft. See Fig. 12.
Installation
1) Lubricate shaft seal with clean refrigerant oil and place
on compressor shaft. Lubricate seal plate and "O" ring (if equipped)
and install in front housing. Install snap ring (if equipped).
2) Place front housing on compressor body. Install through
bolts with new washers. Tighten bolts evenly and alternately to
18 ft. lbs. (24 N.m). Install shaft key using installer and plastic
mallet. Insert dust seal into front of compressor.
3) Install drain plug with new gasket. Add correct amount of
refrigerant oil to compressor. If service valves were removed, coat
new "O" rings with refrigerant oil and install service valves.
4) Place clutch coil on compressor and install snap ring.
Install shims on shaft to adjust pressure plate-to-rotor clearance to
.016-.028" (.41-.71 mm). Tighten shaft nut to 12 ft. lbs. (16 N.m).

A/C COMPRESSOR SERVICING
Article Text (p. 17)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PMFig. 12: Nippondenso 6-Cylinder Compressor
Courtesy of Chrysler Motors.
PANASONIC ROTARY VANE CLUTCH R & I
Removal
1) Insert two 5 mm bolts into threaded holes in armature.
Using screwdriver as a lever in between bolts, remove center bolt.
Remove armature and shims from shaft.
2) remove snap ring. Using puller, remove pulley. Disconnect
electrical leads from field coil. Remove 3 field coil mounting bolts.
Remove field coil.
Inspection
Check friction surfaces for damage from excessive heat or
grooving caused by slippage. Replace parts as necessary. Check coil
winding for shorted or open winding. Clean surfaces with solvent and
dry rag.
Installation
To install, reverse removal procedure. Tighten field coil
retaining screws to 30-56 INCH lbs. (3.4-6.4 N.m). Ensure pulley-to-
armature gap is .016-.024" (.4-.6 mm). If gap is not as specified,