Volkswagen Corrado (1993 year). Manual - part 85

 

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Volkswagen Corrado (1993 year). Manual - part 85

 

 

A/C COMPRESSOR SERVICING 

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 

         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 

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 

         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

 

 

 

 

 

 

 

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