Compressor Clutch: Service and Repair

A/C Clutch -N25-, Servicing (Zexel)

Special tools, workshop equipment, test and measuring appliances and auxiliary items required







- 3212 Two hole pin wrench
- VAG 1719 A/C Clutch set
- VAG 1719/1 Adapter
- VAG 1719/2 Adapter

Not illustrated:
- Torque wrench (5 - 50 Nm)
- Locally available two-arm puller (e.g. Kukko 20-10) with fixtures for a depth of 100 mm.
- Feeler gauge


NOTE:
- Refrigerant circuit does not need to be opened to service A/C clutch.
- If unable to service A/C clutch on compressor installed in vehicle, discharge refrigerant and remove compressor from compressor bracket.







1 - Hex head combination bolt
- 15 Nm (11 ft lb)
- Removing and installing See Fig. 1
2 - Clutch plate
- Removing See Fig. 2
- Checking clutch plate gap See Fig. 6
3 - Shims
- Used to adjust gap between clutch plate and pulley
- Gap: 0.3 - 0.6 mm (0.011 - 0.023 in)
4 - Circlip
- Always replace
- Install correctly: thick side faces compressor
- Ensure correct seating in groove
5 - Clutch pulley
- Removing See Fig. 3
- Installing See Fig. 4
6 - Circlip
- Always replace
- Install correctly: Flat side faces compressor
- Ensure correct seating in groove
7 - Clutch coil
- Installing See Fig. 5


Note: A thermo-fuse is incorporated into the clutch coil. Current to the clutch coil is interrupted in the event of compressor overheating (e.g. a binding compressor).


8 - Felt ring
- Always replace
9 - Bolt
10 - Compressor
- Manufacturer: Zexel


Fig. 1 Combination bolt for clutch plate, removing and installing







- Remove bolt.
- Tightening torque: 15 Nm (11 ft lb)

When removing and installing bolt, counter- hold with 2 hole pin wrench -A- (3212 or equivalent) with pin diameter: 4 mm.

Fig. 2 Clutch plate, removing







- Mount VAG 1719 and turn in center bolt to extract clutch plate.

When removing, counter-hold with 2 hole pin wrench -A- (3212 or equivalent).

Fig. 3 Clutch pulley, removing







- Remove felt ring.
- Fit adapter VAG 1719/1 (or equivalent).
- Fit locally available 2 arm puller -B- on shoulder -A- and extract pulley.

Fig. 4 Clutch pulley, installing







- Drive on belt pulley with plastic head hammer and VAG 1719/2 (or equivalent).

Fig. 5 Clutch coil, installing







- Install coil on compressor.
- Position pin -A- in recess.

Fig. 6 Clutch plate gap, checking







- Check gap with feeler gauge.
- Gap: 0.3 - 0.6 mm (0.011 - 0.023 in)


NOTE:
- Gap must be within tolerance around entire circumference.
- If gap is outside tolerance range, remove clutch plate and adjust gap by adding or removing shims.