A/C Clutch -N25- - Zexel, Servicing

A/C Clutch -N25- - Zexel, Servicing







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.