Volkswagen Corrado (1993 year). Manual - part 86

 

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Volkswagen Corrado (1993 year). Manual - part 86

 

 

A/C COMPRESSOR SERVICING 

         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 

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 

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 

         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

 

 

 

 

 

 

 

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