1993 VOLKSWAGEN CORRADO Repair Manual

A/C COMPRESSOR SERVICING
Article Text
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PM
ARTICLE BEGINNING
1993 AIR CONDITIONING & HEAT
Compressor Servicing
READ THIS FIRST
NOTE: The purpose of this article is to provide GENERAL servicing
overview. For more specific information, refer to the AUTO
A/C-HEAT SYSTEM, MANUAL A/C-HEAT SYSTEM, or HEATER SYSTEM
articles in this section.
NOTE: Due to variety of clutch and shaft seal configurations,
obtain appropriate A/C compressor service tools for
compressor being serviced.
ATSUGI ROTARY VANE CLUTCH COIL 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), remove
clutch disc. When removing pulley, remove lock nut with Hub Socket
(KV99235160).
Installation
1) Tighten center bolt to 81-104 INCH lbs. (9.1-11.8 N.m).
Tighten lock nut to 21-29 ft. lbs. (29-39 N.m). Using feeler gauge,
ensure clearance between clutch disc and pulley is .012-.024" (.30-.60
mm).
2) If clearance is not correct, replace adjustment shim(s).
See Fig. 1. Break-in clutch by engaging and disengaging clutch about
30 times.Fig. 1: Exploded View Of Compressor (Atsugi Rotary Vane)
Courtesy of Nissan Motor Co., U.S.A.

A/C COMPRESSOR SERVICING
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 08:48PM
BOSCH 6-CYLINDER CLUTCH COIL 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 13-15 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-CYLINDER SHAFT SEAL R & I
Removal
Remove clutch plate. Remove shaft key and circlip. Using Seal
Seat Remover/Installer (64 5 030), remove seal seat. Using Seal
Remover/Installer (64 5 040), turn seal slightly clockwise to
disengage tangs and pull out shaft seal. Remove "O" ring seal.
Installation
1) Coat new "O" ring seal with refrigerant oil and install.
Coat new shaft seal with refrigerant oil and install seal on Seal
Remover/Installer(64 5 040). Ensure shaft seal and shaft machine
surfaces align. Insert shaft seal and turn slightly counterclockwise
to secure on shaft.
2) 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: Exploded View Of Compressor Clutch (Bosch 6-Cylinder)
Courtesy of BMW of North America, Inc.

A/C COMPRESSOR SERVICING
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 08:48PM
CALSONIC V5 & V6 CLUTCH COIL R & I
NOTE: Calsonic V6 compressor servicing procedure is not available
from manufacturer.
Removal
1) Remove shaft nut while holding clutch plate with Clutch
Disc Wrench (J-39072). Install clutch disc Puller Set (J-39073-4, J-
33013-1, J-33013-3) and remove clutch plate.
2) Remove snap ring. Use a universal gear puller to remove
clutch pulley. See Fig. 3. Remove screw from clutch coil lead. Use
puller to remove clutch coil.
Installation
1) To install clutch coil, reverse removal procedure. Ensure
coil lead is installed in original position. Using puller set and Coil
Jig (J-39073-1), carefully press clutch coil into place.
2) Install a new clutch pulley snap ring, being careful not
to damage shaft seal. Press clutch plate into place. Install shaft nut
and torque to 89-106 INCH lbs. (10-12 N.m).
3) Use a feeler gauge to check clutch plate-to-pulley
clearance. Clearance should be .012-.024" (.30-.60 mm). If clearance
is too large, remove shaft nut and again press in clutch plate. If
clearance is too small, increase gap by pulling up clutch plate. DO
NOT remove shaft nut.Fig. 3: Exploded View Of Compressor Clutch (Calsonic V5)
Courtesy of Nissan Motor Co., U.S.A.
DIESEL KIKI ROTARY VANE CLUTCH COIL R & I
Removal

A/C COMPRESSOR SERVICING
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 08:48PM
1) Hold clutch disc using Clutch Holder (J-33939) and remove
center bolt. Using Puller (J-33944-A) and Forcing Bolt (J-33944-4),
remove clutch disc. Remove adjustment shim(s) and snap ring.
2) Remove pulley using Pilot (J-38424) and universal puller.
Remove coil lead screw, clutch coil screws and coil. Remove snap ring
and bearing if necessary.
Installation
1) Ensure coil lead is installed in original position.
Install and tighten coil screws to 35-53 INCH lbs. (4-6 N.m). Press
pulley onto compressor using Pulley Installer (J-33940). Install snap
ring and adjustment shim(s).
2) Install clutch disc and tighten center bolt to 106-133
INCH lbs. (12-15 N.m). Using feeler gauge, ensure clearance between
clutch disc and pulley is .012-.024" (.30-.60 mm). If clearance is
incorrect, add or remove shim(s) as necessary. Break-in clutch by
engaging and disengaging clutch 30 times.Fig. 4: Exploded View Of Compressor (Diesel Kiki Rotary Vane)
Courtesy of Nissan Motor Co., U.S.A.

A/C COMPRESSOR SERVICING
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 08:48PM
DIESEL KIKI 6-CYLINDER CLUTCH COIL R & I
NOTE: Due to variety of clutch and shaft seal configurations,
obtain appropriate A/C compressor service tools for
compressor being serviced.
Removal & Installation
1) Using Clutch Holder (J-33939) to prevent clutch disc from
rotating, remove shaft bolt. Using Clutch Disc Puller (J-33944-A) and
Forcing Bolt (J-33944-4), remove clutch disc. Remove shim(s) from
compressor drive shaft or clutch disc. See Fig. 5.
2) Remove snap ring, cover and pulley. With Puller Guide (J-
33943-A) in center of pulley, attach Crossbar (J-8433) to outside
diameter of pulley. Tighten crossbar bolt against puller guide to
remove pulley. Remove coil lead, screws, and coil.
3) To install, reverse removal procedure. Install cover snap
ring with beveled side facing out. Install clutch disc and tighten
center bolt to 133 INCH lbs. (15 N.m).
4) Using feeler gauge, ensure clearance between clutch disc
and pulley is .012-.024" (.30-.60 mm). If clearance is incorrect, add
or remove shim(s) as necessary.
DIESEL KIKI SHAFT SEAL R & I
Removal & Installation
1) Remove clutch coil. Remove and discard felt. Using Shaft
Seal Cover Remover/Installer (J-33942), push down and turn remover
clockwise to engage tangs to cover. Slowly remove seal cover from
bore.
2) Remove shaft seal snap ring. Use Shaft Seal Remover (J-
33942-B) to remove seal. Remove compressor through bolts, front head
and "O" ring. If necessary, replace front and rear valve plates, reed
valves, and "O" rings.
3) To install, reverse removal procedure. Coat "O" ring,
shaft seal and seal seat with refrigerant oil. Place Shaft Seal Guide
(J-34614) over end of compressor shaft. Ensure chamfered portion of
shaft seal retainer aligns with chamfered portion on compressor shaft.
4) Install front head and tighten compressor through bolts,
in a crisscross pattern, to 16 ft. lbs. (22 N.m). Install shaft seal
cover and felt. See Fig. 5. Rotate compressor drive shaft 2-3 times to
ensure compressor operates smoothly.

A/C COMPRESSOR SERVICING
Article Text (p. 6)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PMFig. 5: Exploded View Of Compressor (Diesel Kiki 6-Cylinder)
Courtesy of Isuzu Motor Co.
FORD FX-15 CLUTCH COIL R & I
Removal
1) Using Clutch Holder (000 41 0812 05), remove clutch plate
bolt. Using an 8-mm bolt threaded into clutch plate, remove clutch
plate and shim(s). See Fig. 6.
2) Remove snap ring and pulley assembly. Install Shaft
Protector (49 UN01 047) over shaft seal opening. Use a 2-jaw puller to
remove clutch coil from compressor.
Installation
1) Ensure clutch coil mounting surface is clean. Use Coil
Installer (49 UN01 046) and 2-jaw puller engaged to rear side of
compressor front mounts to press coil into place.
2) Install pulley assembly. Install pulley assembly snap ring
with bevel side of snap ring facing out. Install shim(s) and clutch
plate. Install a new clutch plate bolt and tighten to 97-115 INCH lbs.
(11-13 N.m).
3) Use a feeler gauge to check clearance between clutch plate
and pulley assembly. Clearance should be .018-.033" (.46-.84 mm). If
clearance is incorrect, add or remove shims as necessary.
FORD FX-15 SHAFT SEAL R & I

A/C COMPRESSOR SERVICING
Article Text (p. 7)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PM
Removal
1) Using Clutch Holder (000 41 0812 05), remove clutch plate
bolt. Using an 8-mm bolt threaded into clutch plate, remove clutch
plate and shim(s). See Fig. 6.
2) Remove shaft felt seal. Thoroughly clean seal area of
compressor. Remove shaft seal snap ring. Position Shaft Seal Remover
(49 UN01 044) over compressor shaft.
3) Push shaft seal remover downward against seal. Ensure end
of shaft seal remover is engaged with inside of seal. Rotate shaft
seal remover clockwise to expand remover tip inside seal. Pull shaft
seal from compressor.
Installation
1) Lubricate shaft seal protector and shaft seal with
refrigerant oil. Install shaft seal on shaft seal protector so lip
seal is toward compressor (large end of shaft seal protector).
2) Install shaft seal protector on compressor shaft. Using
Shaft Seal Installer (49 UN01 043), push shaft seal down seal
protector until seal is seated.
3) Remove shaft seal installer and protector. Install a new
shaft seal retaining snap ring and shaft seal felt. Install shim(s)
and clutch plate. Install a new clutch plate retaining bolt and
tighten to 97-115 INCH lbs. (11-13 N.m).
4) Use a feeler gauge to check clearance between clutch plate
and pulley assembly. Clearance should be .018-.033" (.46-.84 mm). If
clearance is incorrect, add or remove shims as necessary.Fig. 6: Exploded View Of Compressor Clutch (Ford FX-15)
Courtesy of Mazda Motors Corp.
HADSYS 7-CYLINDER CLUTCH COIL R & I
Removal
Using Clutch Holder (J-37872), hold pressure plate and remove
shaft bolt. Remove pressure plate and adjustment shim(s). See Fig. 7.
Remove snap ring. Using universal puller, remove compressor pulley.
Remove clutch coil.

A/C COMPRESSOR SERVICING
Article Text (p. 8)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PM
Installation
Install clutch coil in reverse order of removal. Ensure snap
ring is properly seated. Apply locking compound to shaft bolt and
tighten it to 62 INCH lbs. (7 N.m). Ensure clearance between pressure
plate and pulley is 0.012-0.024" (.30-.60 mm). If clearance is
incorrect, add or remove shim(s) as necessary.Fig. 7: Exploded View Of Compressor (Hadsys 7-Cylinder)
Courtesy of American Honda Motor Co., Inc.
HARRISON R4 4-CYLINDER CLUTCH COIL AND BEARING R & I
Removal
1) Clamp Holding Fixture (J-25008-A) in vise. Attach
compressor to holding fixture. Use Clutch Hub Holder (J-33027) to hold
clutch and remove shaft nut.
2) Thread Hub and Drive Plate Assembly Remover/Installer (J-
37707) into hub. Hold body of remover with wrench and turn center bolt