VOLKSWAGEN CORRADO 1993 Repair Manual

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

A/C COMPRESSOR SERVICING
Article Text (p. 9)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PM
into remover body to remove clutch plate and hub assembly. Remove
shaft key and save for installation.
3) Remove snap ring. Place Puller Guide (J-25031-1) in center
of pulley housing. Engage universal puller to outer diameter of pulley
(clutch rotor). See Fig. 8. Hold puller and tighten screw to remove
pulley.
4) Invert pulley and place on work bench. Press out rotor
bearing using handle and Bearing Remover (J-9398-A). Attach universal
puller to outside diameter of clutch coil. Tighten bolt against puller
guide to remove clutch coil.
CAUTION: DO NOT drive or pound on clutch hub or shaft.
Installation
1) Ensure clutch coil is installed in original position.
Press pulley onto compressor using Installer (J-9481-A) and handle.
Install shaft key into hub key groove. Allow key to project
approximately 3/16" (4.8 mm) out of keyway.
2) Ensure frictional surface of clutch plate and clutch rotor
are clean before installing clutch plate and hub assembly. Align shaft
key with shaft keyway and place clutch plate and hub assembly onto
compressor shaft.
3) Hold hub and drive plate remover/installer with wrench and
tighten nut to press hub into shaft until there is a .020-.040" (.5-1.
0 mm) air gap between plate and clutch rotor. Install a new shaft nut
and tighten to 10 ft. lbs. (14 N.m). Ensure rotor is not rubbing on
clutch plate.Fig. 8: Exploded View Of Compressor (Harrison R4 4-Cylinder)
Courtesy of Isuzu Motor Co.
HARRISON V5 5-CYLINDER CLUTCH COIL AND BEARING R & I
Removal
1) Clamp Holding Fixture (J-34992) in vise. Attach compressor
to holding fixture. Use Clutch Hub Holder (J-33027-A) to hold clutch.
Remove shaft nut using Socket (J-33022). See Fig. 9.

A/C COMPRESSOR SERVICING
Article Text (p. 10)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PM
2) Thread Clutch Plate and Hub Assembly Remover (J-33013-B)
into hub. Hold body of remover with wrench and turn center bolt to
remove clutch plate and hub assembly. Remove snap ring. Remove shaft
key and save for installation.
3) Place Puller Guide (J-33023-A) in center of pulley
housing. Engage Rotor/Bearing Puller (J-33020) to inner circle of
slots in pulley (rotor). Hold rotor/bearing puller in place and
tighten screw to remove pulley.
4) Remove screw from rotor/bearing puller. Invert assembly
and place on work bench with rotor/bearing puller still engaged.
Remove hub bearing using handle and Bearing Remover (J-9398-A).
5) With puller guide in place, attach Crossbar (J-8433-1) and
Puller (J-33025) to outside diameter of clutch coil. Tighten crossbar
Bolt (J-8433-3) against puller guide to remove clutch coil.
Installation
1) Ensure clutch coil is installed in original position.
Press coil into position using crossbar, clutch Coil Installer (J-
33024) and Through Bolts (J-34992-2). Stake compressor housing 120
degrees apart to secure coil.
2) Position Rotor/Bearing Installer (J-33017) and puller
guide over inner race of bearing. Using through bolts, assemble
crossbar over puller pilot and tighten through bolts onto holding
fixture. Tighten crossbar bolt to press pulley/bearing assembly onto
compressor.
3) Install shaft key into hub key groove. Allow key to
project approximately 1/8" (3.2 mm) out of keyway. Align shaft key
with shaft keyway and place clutch plate and hub assembly onto
compressor shaft.
CAUTION: Do not drive or pound on clutch hub or compressor shaft, as
compressor could be damaged internally.
4) Hold hex portion of Hub Installer (J-33013) with a wrench.
Tighten center screw to press hub into shaft until there is .020-.030"
(.50-.76 mm) air gap between frictional plate and clutch rotor.
5) Install new shaft nut with small diameter boss of nut
against crankshaft shoulder. Use Socket (J-33022) and Clutch Hub
Holder (J-33027-A). Tighten shaft nut to 12 ft. lbs. (16 N.m). Ensure
pulley does not rub on clutch plate. See Fig. 9.
HARRISON V5 5-CYLINDER SHAFT SEAL R & I
Removal
Remove clutch plate and hub 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 "O" ring from
compressor neck. Thoroughly clean inside of compressor neck and "O"
ring groove.
Installation

A/C COMPRESSOR SERVICING
Article Text (p. 11)
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) 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. Dip shaft seal in
clean refrigerant oil.
2) Place Seal Protector (J-34614) over compressor shaft. Push
new seal over shaft protector. Install new seal snap ring with flat
side against seal. Install clutch plate assembly.Fig. 9: Exploded View Of Compressor (Harrison V5 5-Cylinder)
Courtesy of General Motors Corp.
HITACHI 6-CYLINDER CLUTCH COIL AND SEAL R & I
Removal
1) Hold clutch hub with Clutch Tightener (925770000). Remove
shaft nut from shaft. Using Clutch Hub Remover (926130000), remove
clutch hub. Use snap ring pliers to remove inner snap ring.
2) Remove pulley and bearing assembly. Remove screws securing
clutch coil lead. Remove inner snap ring from clutch coil. Remove
clutch coil from front cover.
3) Remove shaft key. Use snap ring pliers to remove shaft
seal snap ring. Wrap a rag around compressor shaft. Using Injector
Needle (92619000) and refrigerant can, slowly pressurize compressor at
low pressure (suction) service port. See Fig. 10. Catch shaft seal
seat in rag.
4) Insert Shaft Seal Remover/Installer (926120000) through

A/C COMPRESSOR SERVICING
Article Text (p. 12)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PM
open end of front cover. Slowly pull out remover/installer to remove
shaft seal.
Installation
1) Ensure shaft seal contact surface is free of dirt.
Lubricate with refrigerant oil. Using shaft seal remover/installer,
insert shaft seal.
2) To install clutch coil and hub, reverse removal procedure.
Tighten shaft nut to 14-15 ft. lbs. (19-21 N.m). Ensure clearance
between pressure plate and pulley is 0.020-0.031" (.50-.80 mm).Fig. 10: Removing Compressor Shaft Seal Seat (Hitachi 6-Cylinder)
Courtesy of Subaru of America, Inc.
MATSUSHITA ROTARY VANE CLUTCH COIL R & I
Removal & Installation
1) Using Pressure Plate Holder (J-7624) and socket, remove
center bolt. Thread Puller (J-34878) onto pressure plate. Hold
pressure plate with pressure plate holder and tighten puller to remove
pressure plate.
2) Remove shim(s) from shaft. Remove snap ring and, using a
plastic hammer, tap pulley off. Remove screw for clutch coil lead.
Remove snap ring and clutch coil. See Fig. 11.
3) To install, reverse removal procedure. Tighten shaft bolt
to 10 ft. lbs (14 N.m). Using feeler gauge, ensure clearance between
pressure plate and pulley is .014-.026" (.35-.65 mm). If clearance is
incorrect, add or remove shim(s) as necessary.

A/C COMPRESSOR SERVICING
Article Text (p. 13)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PMFig. 11: Exploded View Of Compressor (Matsushita Rotary Vane)
Courtesy of Toyota Motor Sales, U.S.A., Inc.
NIPPONDENSO TV12 ROTARY VANE CLUTCH COIL R & I
Removal
1) Hold clutch disc with Clutch Holder (00007-10331) and
remove shaft nut. Install Clutch Disc Remover (4992-02-020) and remove
clutch disc and shims. See Fig. 12.
2) Remove pulley snap ring and tap pulley (with bearing) off
of compressor with plastic hammer. Remove screw for clutch coil lead.
Remove snap ring and clutch coil.
Installation
To install, reverse removal procedure. Ensure pulley-to-
clutch disc clearance is .016-.024" (.40-.60 mm). If clearance is
incorrect, add or remove shim(s) as necessary.
NIPPONDENSO TV12 DISCHARGE VALVE & SHAFT SEAL R & I
Removal
1) Drain and measure compressor oil in compressor. Remove
discharge valve body through bolts. Remove discharge valve body bolts
and body. Remove discharge valve plate and discharge valve.
2) Remove compressor through bolts and front and rear housing
(oil separator case). Remove pins and gaskets. Remove shaft seal from
shaft. Press shaft seal plate off of front housing (head cover).
Installation
To install components, reverse removal procedure. Tighten

A/C COMPRESSOR SERVICING
Article Text (p. 14)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PM
compressor through bolts to 19 ft. lbs. (26 N.m). Tighten discharge
valve bolts to 41 INCH lbs. (4.6 N.m). Tighten discharge valve body
and body through bolts to 96 INCH lbs. (10.8 N.m).Fig. 12: Exploded View Of Compressor (Nippondenso TV12 Rotary Vane)
Courtesy of Mazda Motors Corp.
NIPPONDENSO 6 & 10-CYLINDER CLUTCH COIL AND BEARING R & I
NOTE: Due to variety of clutch and shaft seal configurations,
obtain appropriate A/C compressor service tools for
compressor being serviced.
Removal
1) Hold clutch plate stationary and remove shaft bolt (or
nut). Remove clutch plate using puller. Remove shim(s) from shaft and
snap ring. Tap pulley off shaft with plastic hammer. If pulley cannot
be removed by hand, use commercially available puller.
2) Remove snap ring, bearing, and seal (if equipped) from
pulley. See Fig. 13. Remove screw for clutch coil lead. Remove snap
ring and clutch coil.
Installation
To install, reverse removal procedure. Ensure snap rings are
installed with beveled side facing out. Tighten shaft bolt (or nut) to