1990 VOLKSWAGEN CORRADO Repair Manual

A/C COMPRESSOR SERVICING
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 09:41PMFig. 1: Atsugi Rotary Vane Compressor
Courtesy of Nissan Motor Co., U.S.A.
BOSCH 6-CYL CLUTCH R & I
Removal
1) Hold clutch plate and remove shaft nut. Using Clutch Plate
Remover (64 5 00), remove clutch plate. Using snap ring pliers, remove
circlip and remove pulley assembly.
2) If pulley bearing is being replaced, remove circlip at
rear of pulley. Press bearing and spacer from pulley. Press in new
bearing with spacer and replace circlip.
Installation
1) Clean all surfaces. Install pulley assembly on compressor
and install circlip. Ensure clutch plate shim is in place on shaft.
Install clutch plate and nut. Tighten nut to 13-14 ft. lbs. (18-20 N.
m).
2) Using a feeler gauge, check clutch plate-to-pulley
clearance. Clearance should be .028-.051" (.7-1.3 mm). If clearance is
not correct, remove clutch plate and replace clutch plate shim. See
Fig. 2.
BOSCH 6-CYL SHAFT SEAL R & I
Removal & Installation
1) Remove clutch plate. Remove shaft key and circlip. Using

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. 7)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PM
Removal
1) Clamp Holding Fixture (J-25008-A) in a vise and attach
compressor to holding fixture with thumb screws. Use Clutch Hub Holder
(J-33027) to hold clutch. Remove shaft nut using Shaft Nut Socket (J-
9399).
2) Thread Clutch Plate and Hub Assembly Remover (J-33013-B)
into hub. Hold body of remover with a wrench and turn center screw
into remover body to remove clutch plate and hub assembly. Remove
shaft key and retain for assembly. See Fig. 5.
NOTE: DO NOT drive or pound on clutch hub or shaft.
Installation
1) Install shaft key into hub key groove. Allow key to
project approximately 1/8" out of key way. Shaft key is curved
slightly to provide an interference fit in hub key groove.
2) Ensure frictional surface of clutch plate and clutch rotor
are clean before installing clutch plate and hub assembly. Align shaft
key with shaft key way and place clutch plate and hub assembly onto
compressor shaft.
3) Hold hex portion of Installer (J-9480-B) with a wrench.
Tighten center screw to press hub into shaft until there is .020-.040"
(.5-1.0 mm) air gap between frictional plate and clutch rotor.
4) Install new shaft nut with small diameter boss of nut
against crankshaft shoulder. Use Thin Wall Socket (J-9399) and Clutch
Hub Holder (J-25030). Tighten shaft nut to 10 ft. lbs. (14 N.m). Spin
pulley rotor by hand to ensure rotor is not rubbing on clutch drive
plate.
HARRISON R4 4-CYL SHAFT SEAL R & I
Removal
1) Clamp Holding Fixture (J-25008-A) in a vise and attach
compressor to holding fixture with thumb screws. Use Clutch Hub Holder
(J-33027) to hold clutch. Remove shaft nut using Shaft Nut Socket (J-
9399).
2) Thread Clutch Plate and Hub Assembly Remover (J-33013-B)
into hub. Hold body of remover with a wrench and turn center screw
into remover body to remove clutch plate and hub assembly. Remove
clutch plate and shaft key. Pry out dust seal (if equipped). Remove
seal seat snap ring. Thoroughly clean compressor neck area and "O"
ring groove surrounding shaft. Any dirt or foreign material may cause
compressor damage.
3) Use Seal Remover/Installer (J23128-A), remove seal with a
twisting motion. Use "O" Ring Remover (J-9553-01) to remove "O" ring.
Installation
1) Coat new shaft seal with refrigerant oil and install shaft
seal on remover/installer. Align compressor shaft machined surface
with shaft seal and install. Turn remover/installer slightly
counterclockwise to secure shaft seal tangs.
2) Using Seal Installer (J-33011), install "O" ring and coat

A/C COMPRESSOR SERVICING
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 09:41PM
with refrigerant oil. Coat seal seat with refrigerant oil and install
using seal seat remover/installer. Install snap ring. Install dust
seal (if supplied in seal kit). See Fig. 5.Fig. 5: Harrison R-4 Radial Compressor
Courtesy of Isuzu Motor Co.
HARRISON V5 5-CYLINDER CLUTCH R & I
Removal
1) Clamp Holding Fixture (J-34992) in vise and attach
compressor to holding fixture with thumb screws. Use Clutch Hub Holder
(J-33027) to hold clutch. Remove shaft nut using Shaft Nut Socket
(J-33022).
2) Thread Clutch Plate and Hub Assembly Remover (J-33013-B)
into hub. Hold body of remover with a wrench and turn center screw
into remover body to remove clutch plate and hub assembly. Remove
shaft key and retain for installation.
Installation
1) Install shaft key into hub key groove. Allow key to
project approximately 1/8" (3.2 mm) out of key way. Shaft key is
curved slightly to provide an interference fit in hub key groove.
2) Ensure frictional surface of clutch plate and clutch rotor
are clean before installing clutch plate and hub assembly. Align shaft
key with shaft key way and place clutch plate and hub assembly onto
compressor shaft.

A/C COMPRESSOR SERVICING
Article Text (p. 9)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PM
NOTE: DO NOT drive or pound on clutch hub or compressor shaft,
as compressor could be damaged internally.
3) Hold hex portion of installer (J-33013) with a wrench.
Tighten center screw to press hub into shaft until there is .015-.025"
(.38-.64 mm) air gap between frictional plate and clutch rotor.
4) Install new shaft nut with a small diameter boss of nut
against crankshaft shoulder. Use Thin Wall Socket (J-9399) and Clutch
Hub Holder (J-25030). Tighten shaft nut to 96-192 INCH lbs.
(11-22 N.m). Spin pulley rotor by hand to ensure rotor is not rubbing
on clutch drive plate. See Fig. 6.
HARRISON V5 5-CYLINDER SHAFT SEAL R & I
Removal
Discharge refrigerant from system using approved refrigerant
recovery/recycling equipment. See SERVICING PRECAUTIONS at beginning
of article. Remove clutch plate assembly. Remove shaft seal snap ring.
Thoroughly clean inside of compressor neck area around shaft and seal.
Engage tangs of Seal Remover/Installer (J-23128-A) into recessed
portion of seal and remove seal. Remove and discard seal "O" ring from
compressor neck. Thoroughly clean inside of compressor neck and "O"
ring groove.
Installation
1) Coat new "O" ring with refrigerant oil and install on "O"
ring installer (J-33011). Install "O" ring into groove in compressor
neck. Attach new seal to Seal Remover/Installer (J-23128-A). Dip seal
in clean refrigerant oil.
2) Place Seal Protector (J-34614) over compressor shaft. Push
new seal over shaft protector. Install new snap ring with flat side
against seal. Install clutch plate assembly.

A/C COMPRESSOR SERVICING
Article Text (p. 10)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PMFig. 6: Exploded View of Harrison V5 5-Cylinder Compressor
Courtesy of General Motors Co.
HITACHI 5 & 6-CYL CLUTCH R & I
Removal
1) Using Clutch Holder (KV99412302), hold clutch hub. Remove
shaft nut from shaft. Using Clutch Hub Remover (KV994C5780), remove
clutch hub.
2) Pry inner snap ring off. Remove pulley and bearing
assembly. If assembly cannot be removed by hand, use Pulley and
Bearing Removers (KV994C5781 and KV994C5782).
3) Remove clamping screws that secure coil assembly leads.
Remove inner snap ring from coil assembly. Remove coil assembly from