VOLKSWAGEN CORRADO 1990 Repair Manual

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

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. 13)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PM
cover at low pressure side of compressor. Connect Pressurizer
(KV994C1552) to can of R-12 refrigerant. Wrap a rag around compressor
shaft. Apply pressure of 28-71 psi (2-5 kg/cmý) at low pressure
(suction) service valve of compressor. Catch shaft seal seat in rag.
See Fig. 8.
NOTE: If shaft seal cannot be pulled out, reset to its original
position, and pressurize again.
4) Insert shaft seal Remover/Installer (KV994C1143) through
the open end of front cover. Depress carbon seal and hook tool at case
projection of shaft seal. Slowly pull out to remove shaft seal. See
Fig. 9.Fig. 8: Hitachi 6-Cylinder Compressor Shaft Seal Seat Removal
Courtesy of Nissan Motor Co., U.S.A.Fig. 9: Hitachi 6-Cylinder Compressor Shaft Seal Removal
Courtesy of Nissan Motor Co., U.S.A.
Inspection
Check carbon seal surface of shaft seal for damage. Check "O"

A/C COMPRESSOR SERVICING
Article Text (p. 14)
1990 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Thursday, March 23, 2000 09:41PM
ring and carbon seal contact surface of shaft seal seat for damage.
Make sure that "O" ring contact surface on front cover is not damaged.
Make sure refrigerant oil is applied to oil seal in shaft seal seat.
Installation
1) To install, reverse removal procedure. Ensure shaft seal
contact surface is free of dirt. Lubricate with refrigerant oil. Cap
end of compressor shaft.
2) Using Guard (KV994C1143), insert shaft seal. Be sure shaft
seal case is aligned with shaft. Apply force to turn seal to left and
right. Ensure shaft seal seats properly in shaft cut-out.
3) Fit "O" ring to outside groove of shaft seal seat. Ensure
"O" ring seats properly. Apply refrigerant oil on contact surfaces and
around shaft seal seat. Lightly coat surface of shaft with refrigerant
oil.
4) Install key on compressor shaft. Using snap ring pliers,
compress retainer ring and fit retainer ring into front cover. Seat
retainer ring firmly in groove. Thoroughly wipe grease or oil from
shaft surface.
5) Connect Installer (KV99412329) to shaft of compressor, and
turn shaft 5 or 6 times in a clockwise direction to seat seal. See
REFRIGERANT OIL & R-12 SPECIFICATIONS chart in this section for system
capacities.
MATSUSHITA ROTARY VANE CLUTCH R & I
Removal & Installation
1) Insert two 5 mm bolts into threaded holes in armature.
Using a screwdriver as lever in between bolts, remove center bolt.
remove armature and shim from shaft.
2) Remove snap ring. Using a puller, remove pulley.
Disconnect electrical leads from field coil. Remove 3 field coil
mounting bolts. Remove field coil. See Fig. 10. To install, reverse
removal procedure.Fig. 10: Exploded View of Rotary Vane Compressor (Matsushita)
Courtesy of Subaru of America. Inc.
NIPPONDENSO TV12 ROTARY VANE CLUTCH R & I