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

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

Special tools and equipment needed







- 3212 Spanner wrench (or equivalent two-hole pin wrench)
- VAG 1719 A/C clutch set
- VAG 1719/1 (included in VAG 1719)
- VAG 1719/2) (included in VAG 1719)

Not illustrated:
- Torque wrench 5 - 50 Nm
- Two arm puller Kukko 20-10 with 100 mm fixtures (or equivalent).
- Feeler gauge (locally available)

NOTE:
- The compressor bracket and related components can be removed and installed without discharging the refrigerant circuit.
- Compressor can only be serviced or replaced after discharging refrigerant system. Use Kent Moore ACR4 or equivalent.







1. Clutch plate bolt
- 15 Nm (11 ft. lb.)
- Removing and installing see Fig. 1
2. Clutch plate
- Removing see Fig. 2
3. Shims
- To adjust gap between clutch plate and pulley
- Gap: 0.3 - 0.6 mm (0.0118 - 0.0236 in.)
- Gap, checking see Fig. 6
4. Circlip
- Always replace
- Flat side must face compressor
- Must be seated correctly in groove
5. Clutch pulley
- Removing see Fig. 3
- Installing see Fig. 4
6. Circlip
- Always replace
- Flat side must face compressor
- Must be seated correctly in groove
7. Clutch coil
- Installing see Fig. 5

NOTE: A thermo-fuse integrated into the clutch coil protects the A/C clutch in the event of overheating (e.g.: due to a binding compressor) The clutch coil circuit is interrupted.

8. Felt gasket
- Always replace
9. Screw
10. Compressor
- Manufacturer: Zexel

A/C clutch -N25- (Zexel), removing and installing

Fig. 1 Clutch plate bolt, removing






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

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

Fig. 2 Clutch plate, removing







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

When removing, counter-hold with two-hole pin wrench -A- (3212 or equivalent with 4 mm pins).

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 (0.0118 - 0.0236 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.