1993 VOLKSWAGEN CORRADO Repair Manual

A/C SYSTEM GENERAL 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 GENERAL SERVICING
General Servicing Procedures
USING R-12 & R-134a REFRIGERANT
HANDLING/SAFETY PRECAUTIONS
1) Always work in a well-ventilated, clean area. Refrigerant
R-134a is colorless and is invisible as a gas. Refrigerant (R-12 or R-
134a) is heavier than oxygen and will displace oxygen in a confined
area. Avoid breathing refrigerant vapors. Exposure may irritate eyes,
nose and throat.
2) The system's high pressure can cause severe injury to eyes
and skin if a hose were to burst. Always wear eye protection when
working around A/C system and refrigerant. If necessary, wear rubber
gloves or other protective clothing.
3) Refrigerant evaporates quickly when exposed to atmosphere,
freezing anything it contacts. If liquid refrigerant contacts eyes or
skin, DO NOT rub eyes or skin. Immediately flush affected area with
cool water for 15 minutes and consult a doctor or hospital.
4) Never use R-134a in combination with compressed air for
leak testing. Pressurized R-134a in the presence of oxygen (air
concentrations greater than 60% by volume) may form a combustible
mixture. DO NOT introduce compressed air into R-134a containers (full
or empty), A/C system components or service equipment.
5) DO NOT expose A/C system components to high temperatures,
steam cleaning for example, as excessive heat will cause
refrigerant/system pressure to increase. Never expose refrigerant
directly to open flame. If refrigerant needs to be warmed, place
bottom of refrigerant tank in warm water. Water temperature MUST NOT
exceed 125øF (52øC).
6) Use care when handling refrigerant containers. DO NOT
drop, strike, puncture or incinerate containers. Use Department Of
Transportation (DOT) approved, DOT 4BW or DOT 4BA, refrigerant
containers.
7) Never overfill refrigerant containers. The safe filling
level of a refrigerant container MUST NOT exceed 60% of the
container's gross weight rating. Store refrigerant containers at
temperature less than 125
øF (52øC).
8) R-12 refrigerant (Freon) will be sold and stored in White
containers, while R-134a refrigerant will be sold and stored in 30 or
50-pound Light Blue containers.
9) R-12 and R-134a refrigerants must never be mixed, as their
desiccants and lubricants are not compatible. If the refrigerants are
mixed, system cross-contamination or A/C system component failure may
occur. Always use separate servicing and refrigerant
recovery/recycling equipment.
10) Follow equipment manufacturer instructions of all service
equipment to be used. The Material Safety Data Sheet (MSDS), provided
by refrigerant manufacturer/suppliers, contains valuable information

A/C SYSTEM GENERAL 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
regarding the safe handling of R-12 or R-134a refrigerants.
IDENTIFYING R-134a SYSTEMS & COMPONENTS
To prevent refrigerant cross-contamination, use following
methods to identify R-134a based systems and components.
Fittings & "O" Rings
All R-134a based A/C systems use 1/2" - 16" ACME threaded
fittings (identifiable by square threads) and quick-connect service
couplings. See Fig. 1. Besides the use of these fittings, most
manufacturers will use Green colored "O" rings in R-134a systems.Fig. 1: R-134a Fittings & Quick Connect Service Couplings ID
Courtesy of Audi of America, Inc.
Underhood A/C Specification Labels
Most R-134a based systems will be identified through the use
of Green or Light Blue underhood labels, or with R-134a refrigerant
clearly printed on labels. See Fig. 2. Some manufacturers will
identify R-12 based systems with White, Red, Silver or Gold underhood
labels. Before servicing an A/C system, always determine which
refrigerant is being used.

A/C SYSTEM GENERAL 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 08:48PMFig. 2: Underhood A/C Specification Labels (Typical)
Courtesy of Nissan Motor Co., U.S.A.
Other Means Of Identification
Refrigerant R-134a, when viewed through a sight glass, may
have a "milky" appearance due to the mixture of refrigerant and
lubricating oil. As the refrigerant and oil DO NOT exhibit a "clear"
sight glass on a properly charged A/C system, R-134a systems have no
sight glass.
Audi, Mercedes-Benz and Volkswagen use Green bands/labels on
condenser, refrigerant lines, receiver-drier and expansion valve.
Lexus A/C system hoses and line connectors have a groove, a White line
and "R-134a" marked on them. See Fig. 3.

A/C SYSTEM GENERAL 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 08:48PMFig. 3: Identifying R-134a Hose & Line Connectors (Lexus)
Courtesy of Toyota Motor Sales, U.S.A., Inc.
REFRIGERANT OILS
Refrigerant R-12 based systems use mineral oil, while R-134a
systems use synthetic/Polyalkylene Glycol (PAG) oils. Using a mineral
oil based lubricant with R-134a will result in A/C compressor failure
due to lack of proper lubrication.
Use ONLY specified oil for the appropriate system and A/C
compressor. Always check the underhood A/C specification label or A/C
compressor label before adding refrigerant oil to A/C
compressor/system. See Fig. 2. The following R-134a refrigerant oils
are currently available.
Lexus
PAG Refrigerant Oil (ND-OIL 8) with 10P/10PA swashplate
(piston) compressor. Synthetic Refrigerant Oil (ND-OIL 9) with
through-vane (rotary vane) compressor.
Mercedes-Benz
PAG Refrigerant Oil (001 989 08 03).
Nissan
PAG Refrigerant Oil (KLH00-PAGR0) with rotary vane
compressor. PAG Refrigerant Oil (KLH00-PAGS0) with piston (swashplate)
compressor.
Saab
PAG Refrigerant Oil (40 74 787).
NOTE: Synthetic/PAG oils absorb moisture very rapidly, 2.3-5.6% by
weight, as compared to a mineral oil absorption rate of
.005% by weight.
SERVICE EQUIPMENT

A/C SYSTEM GENERAL 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
Because R-134a is not interchangeable with R-12, separate
sets of hoses, manifold gauge set and recovery/recycling equipment are
required to service vehicles. This is necessary to avoid cross-
contaminating and damaging system.
All equipment used to service systems using R-134a must meet
SAE standard J1991. The service hoses on the manifold gauge set must
have manual (turn wheel) or automatic back-flow valves at the service
port connector ends. This will prevent refrigerant from being released
into the atmosphere.
For identification purposes, R-134a service hoses must have a
Black stripe along its length and be clearly labeled SAE J2196/R-134a.
The low pressure test hose is Blue with a Black stripe. The high
pressure test hose is Red with a Black stripe, and the center test
hose is Yellow with a Black stripe.
NOTE: Refrigerant R-12 service hoses will ONLY be labeled SAE
J2196.
R-134a manifold gauge sets can be identified by one or all of
the following:
* Labeled FOR USE WITH R-134a on set
* Labeled HFC-134 or R-134a on gauge face
* Light Blue color on gauge face
In addition, pressure/temperature scales on R-134a gauge sets
are different from R-12 manifold gauge sets.
SYSTEM SERVICE VALVES
SCHRADER-TYPE VALVES
NOTE: Although similar in construction and operation to a tire
valve, NEVER replace a Schrader-type valve with a tire valve.
Schrader valve is similar in construction and operation to a
tire valve. When a test gauge hose with built-in valve core depressor
is attached, Schrader stem is pushed inward to the open position and
allows system pressure to reach gauge.
If test hose does not have a built-in core depressor, an
adapter must be used. Never attach hose or adapter to Schrader valve
unless it is first connected to manifold gauge set.
Refrigerant R-12 Schrader-type valve cores have TV5 thread
size. Refrigerant R-134a Schrader-type valve cores use M6 (Metric)
threads. R-134a valve cores can be easily identified by use of "O"
rings and external spring. See Fig. 1.
SERVICE VALVE LOCATIONS
SERVICE VALVE LOCATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄVehicle High Low

A/C SYSTEM GENERAL 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 08:48PM
Audi ........................ (1)(2) .............. (1)(3)
Acura ......................... (2) .................. (3)
BMW ........................... (4) .................. (5)
Chrysler, Eagle & Mitsubishi
Colt, Mirage & Summit ...... (1)(0) ................. (5)
Colt Vista & Summit Wagon .. (1)(0) .............. (1)(1)
Diamante ..................... (4) .................. (5)
Eclipse & Expo ............. (1)(0) .............. (1)(1)
Galant ..................... (1)(0) .............. (1)(1)
Montero .................... (1)(1) .............. (1)(1)
Pickup & Ram-50 ............ (1)(0) .............. (1)(1)
Precis ..................... (1)(0) .............. (1)(0)
Stealth & 3000GT
R-12 ......................... (1) .................. (1)
R-134a ....................... (1) .................. (5)
Ford Motor Co. ................ (4) .................. (5)
General Motors .............. (1)(2) .............. (1)(2)
Geo ........................... (4) .................. (5)
Honda ......................... (4) .................. (5)
Hyundai
Elantra & Scoupe ............. (4) .................. (5)
Excel & Sonata ............. (1)(0) .............. (1)(0)
Infiniti ...................... (4) .................. (5)
Isuzu ......................... (4) .................. (5)
Jaguar ........................ (4) .................. (5)
Lexus ......................... (4) .................. (5)
Mazda
B2200 & B2600i ............... (8) .................. (8)
Miata, MPV Protege & 323 ..... (4) .................. (5)
Navajo ....................... (6) .................. (7)
All Others ................... (1) .................. (1)
Mercedes-Benz ................. (4) .................. (5)
Nissan ........................ (4) .................. (5)
Porsche ....................... (8) .................. (8)
Saab .......................... (8) .................. (8)
Subaru
Impreza ...................... (1) .................. (1)
Legacy & Loyale .............. (4) .................. (5)
SVX .......................... (9) .................. (9)
Suzuki ........................ (4) .................. (5)
Toyota
Pickup & 4Runner ........... (1)(1) .............. (1)(1)
All Others ................... (4) .................. (5)
Volkswagen .................... (4) .................. (5)
Volvo
240, 940 & 960 ............... (4) .................. (5)
850 .......................... (1) .................. (5)
(1) - Information is not available from manufacturer.
(2) - On high pressure line (near top of condenser on Integra;
near receiver-drier on Legend; on receiver-drier on

A/C SYSTEM GENERAL 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
Vigor). Use High-Side Adapter (J-25498).
(3) - On low pressure line (near battery on Integra; near
right rear of engine on Legend; near compressor on
Vigor).
(4) - On high pressure (discharge) hose/line.
(5) - On low pressure (suction) hose/line.
(6) - On high pressure line, between compressor and condenser.
(7) - On suction accumulator/drier.
(8) - On low and high pressure hoses, behind compressor.
(9) - On receiver/drier and low pressure hose (near
compressor).
(1)(0) - On compressor discharge hose and accumulator.
(1)(1) - On compressor discharge and suction ports.
(1)(2) - Front of condenser on right side.
(1)(3) - Towards rear of compressor.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ REFRIGERANT RECOVERY/RECYCLING
Refrigerant recovery/recycling equipment is used to remove
refrigerant from vehicle's A/C system without polluting atmosphere. To
remove and recycle refrigerant, connect the recovery/recycling system
and follow instructions provided with the system.
The removed refrigerant is filtered, dried and stored in a
tank within the recovery/recycling system until it is ready to be
pumped back into the vehicle's A/C system. With refrigerant stored in
the recovery/recycling system, A/C system can be opened without
polluting atmosphere.
NOTE: Separate sets of hoses, gauges and refrigerant
recovery/recycling equipment MUST be used for R-12 and
R-134a based systems. DO NOT mix R-12 and R-134a
refrigerants, as their refrigerant oils and desiccants are
not compatible. On systems with R-134a refrigerant, use
Polyalkylene Glycol (PAG) wax-free refrigerant oil.
END OF ARTICLE

A/C-HEATER SYSTEM - MANUAL
Article Text
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:49PM
ARTICLE BEGINNING
1993 MANUAL A/C-HEATER SYSTEMS
Volkswagen United States, Inc.
Corrado SLC
SPECIFICATIONS
SPECIFICATIONS TABLEÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Specification
Compressor Type ........................ Sanden SD-709 7-Cyl.
Compressor Belt Tension (1)
System Oil Capacity (2) ........................ 3.9-4.4 ozs.
Refrigerant (R-134a) Capacity ................ 35.0-36.6 ozs.
System Operating Pressures
High Side ............................ 203 psi (13.8 kg/cm
ý)
Low Side ............................... 17 psi (1.1 kg/cm
ý)
(1) - Ribbed belt uses automatic belt tensioner.
(2) - Use PAG Compressor Oil (Part No. G 052 154 A2).
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄWARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM procedures.
AIR BAG SYSTEM PRECAUTIONS
SYSTEM OPERATION CHECK
Two lights pertaining to air bag system are located directly
above air bag symbol in instrument cluster. Control light is used to
indicate readiness of system. With ignition on, control light comes on
for about 5-8 seconds then goes out, while diagnosis unit in air bag
control unit performs an electronic test cycle of system.
If control light does not function as described, a fault
probably exists in system. If fault occurs while ignition is on, it
will be stored in fault memory. Warning light will then come on, and
air bag system will be switched off. If warning light comes on or
flickers while driving, air bag system should be tested.
SERVICE PRECAUTIONS
Observe these precautions when working with air bag systems:
* DO NOT use computer memory saver tool. Using computer memory
tool will keep air bag system active and may cause accidental
deployment of air bag unit.