A/C Compressor Clutch - Removal and Installation
Group: 87Number: 91-04
Date: April 30, 1991
Subject:
A/C Compressor Clutch, removing and installing
Models:
Passat, Corrado from 1990 m.y.
Golf, GTI, Jetta, GLI, (GTX in Canada) from 1985 m.y.
Cabriolet, Vanagon from 1984 m.y.
Condition
General Information
A/C compressors are now only available without clutch assemblies.
Service
Note:
Compressor repairs must be performed on a clean dry service bench with a vise.
WARNING:
Follow all recommended safety precautions listed in the Repair Manual Microfiche to avoid injury.
WARNING
Automotive refrigerants containing CFC's are hazardous to the earth's atmosphere. To protect our environment, use an Underwriter's Laboratory (UL) approved refrigerant recovery/recycling unit such as Kent-Moore ACR 3, or equivalent, whenever discharging an A/C system.
WARNING
The A/C system should only be serviced by trained personnel familiar with:
^ equipment use
^ related safety procedures
^ regulations governing the discharge handling and disposal of automotive refrigerants.
Tools and Compressor Exploded View
CAUTION:
Always follow manufacturer's instructions when using a refrigerant recovery/recycling unit.
^ Discharge A/C refrigerant system, use refrigerant recovery/recycling unit.
Note:
If the vehicle has no refrigerant in the A/C system "as received", the receiver drier must be replaced.
^ Remove A/C lines from compressor.
^ Plug A/C lines with a suitable plug to prevent contaminating of the receiver drier with moisture.
^ Remove compressor from vehicle.
Note:
When servicing A/C compressors, verify the model number of the compressor, i.e. SD-508 or SD-709, to insure correct replacement parts are ordered. Many older Vanagons may have been upgraded to the seven cylinder compressor (SD-709). VIN information on the parts microfiche will not reflect these upgrades, therefore it is necessary to use the Sanden Model Number located on the compressor label.
A/C Compressor Clutch Removal
Note:
Refer to Tools and Compressor Exploded View for all compressor part and tool call outs.
^ Insert spanner wrench (Mastercool tool No. 90901 or equivalent) into clutch front plate (18) of compressor.
^ Hold plate stationary with spanner and remove 19 mm hex nut (19) from compressor shaft with 19 mm socket wrench.
^ Remove clutch front plate (18) with clutch plate puller (Mastercool tool No. 90902 or equivalent).
^ Remove bearing dust cover, if equipped, with screwdriver.
Note:
Be careful; avoid distorting dust cover when removing.
^ Remove shaft key (17) by lightly tapping with slotted screwdriver and small hammer.
^ Remove all clutch shims (14, 15, 16) from compressor shaft.
^ Remove bearing snap ring (13) with snap ring pliers (Mastercool tool No. 90903 or equivalent).
^ Remove rotor pulley (12) with puller US 1078.
^ Loosen field coil wire clamp (10) and connector holder, if equipped.
^ Remove field coil retainer snap ring (11) with snap ring pliers (Mastercool tool No. 90903 or equivalent).
^ Remove clutch field coil (9).
Clutch Installation
^ Install clutch field coil (9).
^ Field coil flange protrusion must match hole in front of compressor housing to prevent coil movement, and to correctly locate power leads for attachment.
^ Install clutch field coil retainer snap ring (11) with snap ring pliers.
^ Attach field coil wire clamp (10) and connector holder, if equipped.
^ Support compressor on mounting tabs at base of compressor in bench vise.
^ Align pulley (12) on front housing hub squarely.
^ Install pulley, use YW 519. Make certain the outer edge of ring rests firmly on inner race of rotor bearing.
^ Tap with a small hammer on the end of VW 519 while guiding pulley (12) to prevent binding.
^ Tap VW 519 until pulley (12) bottoms out against compressor front housing hub.
^ Install snap ring (11) with snap ring - pliers (Mastercool tool No. 90903 or equivalent).
^ Install shims (14, 15, 16) removed earlier in procedure.
^ Install shaft key (17) with small hammer and screwdriver.
^ Install bearing dust cover, if equipped.
^ Align front plate keyway to compressor shaft key (17).
^ Install front clutch plate (18) onto compressor - shaft.
^ Install shaft protector (Mastercool tool No. 90910 or equivalent) on to compressor shaft and tap on shaft protector with a small hammer to install front clutch plate (18) on to compressor shaft, until it has bottomed on shims (14, 15, 16).
^ Install 19 mm hex nut (19) on to compressor shaft.
^ Insert spanner wrench (Mastercool tool No. 90901 or equivalent) into holes of front clutch plate and hold stationary.
CAUTION:
Use a beam type torque wrench. Damage may result from use of inaccurate "click" wrenches.
^ Tighten hex nut (19).
^ Tightening Torque: 30-34 Nm (22-25 ft. lb.)
^ Check air gap (a) of clutch with feeler gauge (Mastercool tool No. 91146 or equivalent).
^ (a) - 0.40 mm to 0.80 mm gap (0.016 in. to 0.031 in.)
^ If air gap (a) is not consistent around the circumference, lightly pry up on the front face plate at the low spots and lightly tap down on the high spots with a small hammer.
Note:
The air gap (a) is determined by the spacer shims (14, 15, 16). When installing a clutch assembly, try the original shims first. When installing a new clutch on a new compressor use the 1 mm, 0.5 mm, and the 0.127 mm shims provided in the clutch installation kit. If the air gap does not meet specification, add or subtract shims accordingly.
A/C Clutch Removal/Installation
Labor Operation Number: 87 27 11 0
Suggested Repair Time: 55 TU
^ Lubricate all 0-rings on compressor fittings with clean refrigerant oil.
^ Install compressor in vehicle.
Note:
Refer to Group 87 of the Repair Manual Microfiche for all mechanical installation instructions including belt tensioning.
^ Remove plugs from A/C lines.
^ Install A/C lines to compressor.
^ Tightening Torque: Suction 35 Nm Discharge 25 Nm.
^ Evacuate and charge A/C system.
Evacuate and Charge A/C System
Labor Operation Number: 87 01 61 0
Suggested Repair Time: 75 TU