Zexel Compressor

A/C Clutch -N25-, Servicing

CAUTION:
- Do Not open A/C refrigerant system to service A/C clutch. Instead, remove compressor from mounting bracket without removing refrigerant pipes.
- Mark running direction of ribbed belt before removing. Ribbed belt could break if allowed to run in reverse direction.

Preparation
- Remove compressor from bracket:
- 4-cyl. engine.
- 6-cyl. engine.

A/C Clutch, servicing:


Zexel Compressor







NOTE: A/C clutch versions may differ slightly from illustration. Servicing procedures remain the same.

1 - Clutch plate bolt - 15 Nm
- Removing and installing See Fig. 1.
2 - Clutch plate
- Removing See Fig. 2.
3 - Shims
- For adjusting gap between clutch plate and belt pulley
- Gap: 0.4 - 0.6 mm
- Checking/adjusting gap See Fig. 6.
4 - Circlip
- Always replace
- Must be installed correctly (flat side toward compressor)
- Must be properly seated in groove
5 - Ribbed belt pulley
- Removing See Fig. 3.
- Installing See Fig. 4.
6 - Circlip
- Always replace
- Must be installed correctly (flat side toward compressor)
- Must be properly seated in groove
7 - Magnetic coil
- Installing See Fig. 5.
8 - Felt ring
- Always replace
9 - Bolt
10 - A/C Compressor
- Zexel







Fig. 1 Clutch plate bolt, removing and installing
- Use commercially available two-pin wrench (illustrated -A-) to counter-hold clutch plate. (locating pins dia 4 mm).

Tightening torque: 15 Nm (11 ft. lb.).







Fig. 2 Clutch plate, removing
- Use commercially available two-pin wrench (illustrated -A-) and fixture from A/C clutch set VAG 1719 to counter-hold clutch plate







Fig. 3 Ribbed belt pulley, removing
- Remove felt ring.
- Insert fixture VAG 1719/1 as illustrated.
- Attach commercially available two-arm puller -B- at shoulder -A- and remove pulley.

NOTE: To avoid damaging pulley when removing, make sure the puller is properly fitted to shoulder -A-.







Fig. 4 Ribbed belt pulley, installing
- Clean contact surface before installing.
- Insert fixture VAG 1719/2.
- Carefully tap pulley into place using plastic hammer.







Fig. 5 Magnetic coil, installing
- Fit lug into recess on magnetic coil -A-.







Fig. 6 Clutch plate gap, checking
- Check gap between ribbed belt pulley and clutch plate:
- Gap = 0.3 - 0.6 mm

NOTE:
- The gap width must be within the tolerances around the whole circumference.
- The gap width can also be measured without removing the compressor (compressor installed).
- If the gap width is outside the specified tolerance, remove the clutch plate and adjust the gap width by removing or adding shims.