VOLKSWAGEN CORRADO 1993 Repair Manual

A/C COMPRESSOR SERVICING
Article Text (p. 15)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PM
13-14 ft. lbs. (17-19 N.m) on Fox, MR2 and Scoupe; 10-13 ft. lbs. (14-
17 N.m) on all others. Ensure air gap between clutch plate and pulley
is .024-.040" (.60-1.00 mm) on Fox and MR2; .014-.026" (.36-.66 mm) on
all others. If air gap is incorrect, add or remove shim(s) as
necessary.
NOTE: To check air gap, place a dial indicator on clutch plate.
Apply voltage to clutch coil. Check air gap between clutch
plate and drive pulley. Ensure air gap is as specified.Fig. 13: Exploded View Of Compressor (Nippondenso 10-Cylinder)
Courtesy of Ford Motor Co.
NIPPONDENSO 6 & 10-CYLINDER SHAFT SEAL R & I
NOTE: On Chrysler and Mitsubishi, remove compressor through bolts
and front housing to remove shaft seal. See Fig. 14.
Alternately tighten through bolts to 18-21 ft. lbs. (24-28
N.m).
Removal
1) Remove clutch plate and pulley. Remove shim(s) from shaft.
Remove clutch coil if necessary. Remove felt and felt retainer (if
equipped). Place shaft key remover on shaft and turn to remove key.

A/C COMPRESSOR SERVICING
Article Text (p. 16)
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) Remove seal plate snap ring. Engage plate remover on seal
plate and pull up to remove seal plate. Engage shaft seal
remover/installer to shaft seal and pull up to remove shaft seal from
front housing.
Installation
1) Apply clean refrigerant oil to compressor housing bore.
Lubricate shaft seal with refrigerant oil and install in front
housing. Lubricate seal plate and install in front housing.
2) Install shaft key, snap ring, felt retainer and felt. With
clutch plate installed, ensure air gap between clutch plate and pulley
is .024-.040" (.60-1.00 mm) on Fox and MR2; .014-.026" (.36-.66 mm) on
all others. If air gap is incorrect, add or remove shim(s) as
necessary.Fig. 14: Exploded View Of Compressor (Nippondenso 10PA15 10-Cylinder)
Courtesy of Chrysler Corp.
PANASONIC ROTARY VANE CLUTCH COIL R & I
Removal
Hold clutch disc stationary and remove shaft bolt. Remove
clutch disc and shim(s) from shaft. Remove snap ring. Using a puller,
remove pulley. Remove screw from clutch coil lead. Remove screws and
field coil.
Installation
To install, reverse removal procedure. Tighten field coil
screws to 30-57 INCH lbs. (3.4-6.4 N.m). Ensure pulley-to-armature gap
is .016-.020" (.40-.50 mm). If air gap is incorrect, add or remove
shim(s) as necessary. Tighten shaft bolt to 97-115 INCH lbs. (11-13 N.
m).
PANASONIC ROTARY VANE DISCHARGE VALVE R & I
Removal & Installation
Remove compressor head cover. Remove discharge valve stopper
and discharge valve. See Fig. 15. Install replacement discharge valve
and stopper, reversing removal procedure. Tighten discharge valve
bolts to 27-34 INCH lbs. (3.0-3.8 N.m). Tighten compressor head cover

A/C COMPRESSOR SERVICING
Article Text (p. 17)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PM
bolts to 89 INCH lbs. (10 N.m).Fig. 15: Exploded View Of Compressor (Panasonic Rotary Vane)
Courtesy of Mazda Motors Corp.
PANASONIC ROTARY VANE OIL CONTROL VALVE R & I
Removal & Installation
Remove compressor rear cover. Remove oil control valve.
Remove springs, valve, and rear cover seal. To install components,
reverse removal procedure. Tighten oil control valve bolts to 89 INCH
lbs. (10 N.m). Tighten rear cover nuts to 21 ft. lbs. (29 N.m) and
bolts to 89 INCH lbs. (10 N.m).
PANASONIC ROTARY VANE SHAFT SEAL R & I
Removal & Installation
Remove clutch disc and shim(s). Remove felt seal and snap
ring. Using Seal Plate Remover (49 B061 005), engage and remove shaft
seal plate. Remove shaft seal with Seal Remover/Installer (49 B061
006). To install, reverse removal procedure. Coat new seal plate and
seal with clean refrigerant oil. DO NOT touch seal surfaces with
fingers.
SANDEN SCROLL CLUTCH COIL AND SHAFT SEAL R & I
NOTE: Due to variety of clutch and shaft seal configurations,
obtain appropriate A/C compressor service tools for
compressor being serviced.
Removal (Chrysler & Mitsubishi Except Galant & Mirage)
1) Remove drive belt pulley (if equipped). Hold clutch plate

A/C COMPRESSOR SERVICING
Article Text (p. 18)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PM
using Pliers (MB991367) and Bolts (MB991386). Use a ratchet and socket
to remove clutch hub nut.
2) Remove clutch plate. Remove snap ring with internal snap
ring pliers. Remove clutch hub (rotor). Remove snap ring and clutch
coil.
3) Using an awl, remove bearing cover and retainer. Using
Bearing Remover (MB991456), engage bearing grooves. Place base of
bearing remover over remover arms and tighten nut.
4) Tighten bearing remover bolt to withdraw bearing from
compressor. Engage grooves of Shaft Seal Remover/Installer (MB991458)
and pull straight up on shaft seal.
Installation (Chrysler & Mitsubishi Except Galant & Mirage)
1) To install shaft seal, ensure front housing is free of
foreign objects. Lubricate Shaft Seal Protector (MB991459) and place
over compressor shaft. Lubricate shaft seal and install using shaft
seal remover/installer. Remove shaft seal protector.
2) Using a 21 mm socket or Drift (MB991301), carefully press
bearing onto compressor shaft. Install clutch coil so that alignment
pin is engaged. Install clutch coil snap ring with tapered side facing
out.
3) Align armature plate with crankshaft spline. Tighten shaft
nut to 12 ft. lbs (16 N.m). Using feeler gauge, ensure clearance
between pressure plate and pulley is .016-.024" (.40-0.60 mm). If
clearance is incorrect, add or remove shim(s) as necessary.Fig. 16: Exploded View Of Compressor (Sanden Scroll)
Courtesy of Chrysler Corp.
Removal (Chrysler & Mitsubishi Galant & Mirage)

A/C COMPRESSOR SERVICING
Article Text (p. 19)
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 plate by securing 2 box-end wrenches with two
6-mm bolts, 1" (25 mm) or longer. Holding bow-end wrenches, use a
ratchet and socket to remove clutch hub nut.
2) Remove clutch plate. See Fig. 17. Remove snap ring with
internal snap ring pliers. Remove clutch hub. Remove snap ring and
clutch coil.
3) Remove front housing bolts. Remove front housing and "O"
ring from compressor. Remove shaft seal from shaft. Remove snap ring
from back side of front housing. Remove seal plate. Use brass drift
and hammer to lightly tap shaft bearing from front housing. Remove
felt seal.
NOTE: DO NOT touch sealing surfaces of shaft seal carbon ring and
shaft seal plate.
Installation (Chrysler & Mitsubishi Galant & Mirage)
1) Lubricate shaft seal with compressor oil. Align notches on
shaft seal with notches on shaft. Install shaft seal plate on front
housing. Install front seal housing to compressor.
2) Use Drift (MB991301) to install felt into front housing.
Ensure metal ring on felt faces up. Use drift to press bearing into
front housing.
3) Align and install clutch coil. Install snap ring so
tapered surface faces outward. Install clutch hub. Install snap ring.
Align clutch plate mark with shaft; where there are no splines on
shaft.
4) Tighten clutch hub nut to 12 ft. lbs. (16 N.m). Using
feeler gauge, measure clutch plate-to-clutch hub gap. If gap is not .
012-.024" (.30-.60 mm), remove clutch assembly and add or remove
shim(s).Fig. 17: Exploded View Of Compressor (Sanden FX105V Scroll)
Courtesy of Chrysler Corp.

A/C COMPRESSOR SERVICING
Article Text (p. 20)
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 & Installation (Honda & Hyundai)
1) Remove shaft nut while holding clutch plate with Armature
Holder (J-37872). Using Puller (07935-8050003), remove pressure plate
and shim(s). See Fig. 16. Remove snap ring.
2) Place Seal Driver (07945-4150200) in center of pulley.
Engage universal puller to outer diameter of pulley. DO NOT engage
puller on belt area. Hold puller in place and tighten screw to remove
pulley. Remove screw for clutch coil lead. Remove snap ring and clutch
coil.
3) To install clutch coil, reverse removal procedure. Align
lug on clutch coil with hole in compressor. Install snap rings with
chamfered side facing out. Tighten shaft nut to 12-14 ft. lbs. (16-19
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.
NOTE: Shaft seal removal and installation procedures not available
from Honda or Hyundai.
SANDEN 5-CYLINDER CLUTCH COIL R & I
Removal
1) Hold clutch plate, using Holder (0000-41-0809-01), and
remove shaft nut. Remove clutch plate using Puller (0000-41-0809-02).
Remove shaft key and shim(s). Remove external front housing snap ring
and internal bearing snap ring (if used).
2) Install Clutch Pilot (0000-41-0810-77), Pulley/Clutch
Remover (0000-41-0810-76), and Puller (0000-41-0804-51/57) to remove
pulley assembly. Remove snap ring and drive bearing out of pulley.
Remove screw for clutch coil lead. Remove snap ring and clutch coil.
Installation
1) Install new bearing, ensuring Bearing Installer (000-41-
0804-43) contacts outer race of bearing. Install snap ring and ensure
bearing turns freely.
2) Install clutch coil, ensuring lug on coil aligns with hole
in front housing. Support compressor on rear mounting ears. Align
rotor on front housing hub. Use bearing installer and Driver (0000-41-
0810-59) to install pulley. With pulley seated, install snap ring(s).
Install shim(s) and shaft key.
3) Place clutch plate over shaft and, using Shaft Protector
(0000-41-0809-10), tap clutch plate into place. Install and tighten
shaft nut to 25-32 ft. lbs. (34-44 N.m). Using feeler gauge, ensure
clearance between clutch plate and pulley is .016-.032" (.40-.80 mm).
If clearance is incorrect, add or remove shim(s) as necessary.
SANDEN 5-CYLINDER CYLINDER HEAD & VALVE PLATE R & I
Removal & Installation
Remove compressor cylinder head (rear cover) bolts. Carefully
pry cylinder head of compressor. Remove reed valve plate and gasket.
To install components, reverse removal procedure. Tighten compressor

A/C COMPRESSOR SERVICING
Article Text (p. 21)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PM
cylinder head bolts, in a crisscross pattern, to 21-29 ft. lbs. (29-39
N.m).
SANDEN 5-CYLINDER SHAFT SEAL R & I
Removal
Remove shaft nut and clutch plate. Remove shaft key and
shim(s). Carefully remove felt ring. Remove shaft seal seat snap ring.
Using Seal Seat Remover/Installer (0000-41-0810-73), carefully remove
seal seat. Using Shaft Seal Remover/Installer (0000-41-0812-11),
carefully remove shaft seal.
Installation
1) Install Seal Protector (0000-41-0812-13) over shaft. Place
new seal on remover/installer. DO NOT touch carbon sealing surface
with fingers. Dip seal in refrigerant oil and install. Remove seal
installer by turning counterclockwise.
2) Coat seal seat with refrigerant oil. Install seal seat
using remover/installer. Install seal seat snap ring (with flat side
down). Install shim(s), felt ring and shaft key. Install shaft nut and
clutch plate. Ensure clearance between clutch plate and pulley is .
016-.032" (.40-.80 mm). If clearance is incorrect, add or remove
shim(s) as necessary.
SANDEN 7-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) Install two 6-mm bolts, 1" (25 mm) or longer, in clutch
plate holes. Using 2 box-end wrenches to hold bolts and to prevent
clutch plate from turning, remove shaft nut.
2) Remove clutch plate using Clutch Plate Puller (09977-
21100). Remove clutch shim(s) and bearing dust cover. Remove external
front housing snap ring. See Fig. 18.
3) Remove pulley using universal puller. Detach clutch coil
lead from compressor housing. Remove clutch coil snap ring and clutch
coil. If necessary, remove snap ring and bearing.
Installation
1) Align clutch coil lug with hole in compressor housing, and
install clutch coil. Install clutch coil snap ring. Install drive
pulley using Drive Pulley Installer (09977-21811).
2) Install external bearing snap ring. Using Seal Installer
(09977-21800), install bearing dust cover. After dust cover
installation, ensure there is no contact between cover and front
housing.
3) Install clutch shim(s) and clutch plate. Tighten shaft nut
to 13-14 ft. lbs. (17-19 N.m). Using a dial indicator, check air gap
between clutch plate and drive pulley. Apply voltage to clutch coil.

A/C COMPRESSOR SERVICING
Article Text (p. 22)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PM
Ensure air gap is .016-.032" (.40-.80 mm). If clearance is incorrect,
add or remove shim(s) as necessary.
NOTE: If compressor valve plate is serviced, tighten compressor
cylinder head bolts to 25-26 ft. lbs. (34-35 N.m).Fig. 18: Exploded View Of Compressor (Sanden 7-Cylinder)
Courtesy of Hyundai Motor Co.
SANDEN 7-CYLINDER SHAFT SEAL R & I
NOTE: Check compressor refrigerant oil level when replacing seals.
See COMPRESSOR OIL CHECKING article in GENERAL SERVICING.
Removal
1) Remove clutch plate, shim(s) and bearing dust cover. Tap
shaft key out of slot in compressor shaft. Remove seal retainer felt
ring.
2) Remove shaft seal seat snap ring. Insert Seal Seat
Remover/Installer (09977-21400) into front housing and turn to engage
tangs on seat. Lift seal seat out.
3) Insert Seal Remover/Installer (09977-21510) into front
housing and turn to engage tangs on seal. Carefully lift shaft seal
out without scratching compressor shaft.
Installation
1) Install Shaft Seal Guide Sleeve (09977-21700) over
compressor shaft. Dip seal in refrigerant oil and install seal on
sleeve. Using seal remover/installer, rotate seal clockwise until seal
is engaged. Remove seal remover/installer by turning it

A/C COMPRESSOR SERVICING
Article Text (p. 23)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PM
counterclockwise.
2) Coat seal seat with refrigerant oil and install seal with
seal seat remover/installer. Remove shaft seal guide sleeve. Install
snap ring with beveled edge facing out. Install seal retainer felt
ring using seal seat remover/installer.
3) Install shaft key and clutch plate. Tighten shaft nut to
13-14 ft. lbs. (17-19 N.m). Using a dial indicator, check air gap
between clutch plate and drive pulley. Apply voltage to clutch coil.
Ensure air gap is .016-.032" (.40-.80 mm). If clearance is incorrect,
add or remove shim(s) as necessary.
SEIKO-SEIKI ROTARY VANE
NOTE: Volvo Seiko-Seiki compressor servicing procedure is not
available from manufacturer.
ZEXEL ROTARY VANE CLUTCH COIL AND BEARING R & I
Removal
1) Hold clutch disc using Clutch Disc Wrench (KV99231260) and
remove center bolt. Using Clutch Disc Puller (KV99232340), remove
drive plate and adjustment shim(s).
2) Remove snap ring. Remove pulley using Pilot (J-39023) and
universal puller. Remove clutch coil. If necessary, remove snap ring
and bearing. See Fig. 19.
Installation
1) Ensure coil lead is installed in original position.
Install and tighten coil screws. 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 11-13 ft.
lbs. (15-18 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.
NOTE: Shaft seal assembly servicing procedure is not available
from manufacturer. Use exploded view as a guide. See
Fig. 19. Tighten thermal protector, if removed, to
11-13 ft.lbs. (15-18 N.m).

A/C COMPRESSOR SERVICING
Article Text (p. 24)
1993 Volkswagen Corrado
For Volkswagen Technical Site: http://vw.belcom.ru
Copyright © 1998 Mitchell Repair Information Company, LLC
Wednesday, March 22, 2000 08:48PMFig. 19: Exploded View Of Compressor (Zexel Rotary Vane)
Courtesy of Nissan Motor Co., U.S.A.
ZEXEL 6-CYLINDER CLUTCH COIL AND BEARING R & I
NOTE: Volvo Zexel compressor servicing procedure is not available
from manufacturer.
Removal (Audi)
1) Using Spanner Wrench (44-4), hold clutch hub stationary
and remove shaft bolt. Remove clutch plate and shim(s) using Puller
(VAG 1719) and Spanner Wrench (3212). See Fig. 20. Remove snap ring.
2) Place Spacer (VAG 1719/1) in center of pulley cavity.
Attach Puller (US 1078) to outer diameter of pulley and remove pulley.
Remove snap ring, bearing, and clutch coil as necessary.
Installation (Audi)
Ensure clutch coil lug fits into hole on compressor housing.
Using Installer (VAG 1719/2), press on pulley and install snap ring.
Install shim(s) and clutch plate. Tighten shaft bolt to 11 ft. lbs.
(15 N.m). Using feeler gauge, ensure air gap between pulley and clutch
disc is .012-.024" (.30-.60 mm). If clearance is incorrect, add or
remove shim(s) as necessary.