Volkswagen Corrado (1993 year). Manual - part 89

 

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Volkswagen Corrado (1993 year). Manual - part 89

 

 

A/C COMPRESSOR SERVICING 

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 

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 

         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 

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

 

 

 

 

 

 

 

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