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

A/C Clutch -N25-, Servicing - Zexel Compressor

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.







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

1 Clutch plate bolt - 15 Nm
- Refer Fig. 1 given below
2 Clutch plate
- Refer Fig. 2 given below
3 Shims
- For adjusting gap between clutch plate and belt pulley
- Gap: 0.4 - 0.6 mm
- Refer to Fig. 6 given below
4 Circlip
- Always replace
- Must be installed correctly (flat side toward compressor)
- Must be properly seated in groove
5 Ribbed belt pulley
- Refer Fig. 3 given below
- Refer Fig. 4 given below
6 Circlip
- Always replace
- Must be installed correctly (flat side toward compressor)
- Must be properly seated in groove
7 Magnetic coil
- Refer Fig. 5 given below
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 counterhold clutch plate. (locating pins 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.