Servicing magnetic coupling -N25- when compressor is removed; Manufacturer Sanden — VW

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

3212 Two hole pin wrench
VW 401 Press plate
VW 402 Press plate
VW 412 Press piece
VW 432 Press piece
VW 441 Base plate

Not illustrated:

Commercially available two-arm puller e.g. Kukko 20-10 with arms for a depth of 100 mm.

V.A.G 1616 Counter-hold tool for coupling plate

V.A.G 1616/1 Puller for magnetic coupling

Perform following work first:

Extract refrigerant with Service station V.A.G 1885.

Note:

Draining the refrigerant into the environment is a punishable offence.

Take air conditioner compressor off bracket =>Removing and installing bracket for air conditioner compressor

Hexagon nut
20 Nm
Self-locking
Replacing
Undoing =>Fig.
1

Coupling plate
Pulling off =>Fig.
2
Checking clearance =>Fig.
7

Circlip
Replacing

Install correctly:
Flat side faces compressor

Ensure seated correctly in groove

Belt pulley
Pulling off =>Fig.
3
Pressing on =>Fig.
6

Ball bearing
Pressing off =>Fig.
4
Pressing in =>Fig.
5

Circlip
Replacing

Install correctly:
Flat side faces compressor

Ensure seated correctly in groove

Circlip
Replacing

Install correctly:
Flat side faces compressor

Ensure seated correctly in groove

Magnet windings
Locked with fitted pin
Secured with circlip -
7
-

Notes:

An overheating protection is installed in the magnet windings. The overheating protection interrupts the magnet windings as soon as the magnetic coupling overheats (for example a binding compressor).

Spacers
To adjust the clearance between coupling and belt pulley
Checking clearance =>Fig.
7

Woodruff key
Compressor
SD7-V16 compressor
From 01.95 gradual introduction
SD7-H15 compressor
Up to 01.95

Removing magnetic coupling from compressor and reinstalling

Fig.1
Undoing hexagon nut

Use counter-hold for coupling plate 3212 or V.A.G 1616 and undo hexagon nut.

Fig.2
Pulling off coupling plate

Note:

The three hexagon bolts of the V.A.G 1616/1 have a 1/4" thread.

Fig.3
Pulling off belt pulley for magnetic coupling

Locate hooks -arrow- as shown in illustration.

Note:

If the hooks are fitted on the lower edge of the belt pulley, there is a danger of damaging the magnetic coupling -N25- coil.

Pull off belt pulley with a commercially available tow-arm puller, e.g. Kukko 20-10 with arms for a depth of 100 mm.

Fig.4
Pressing off ball bearing

Fig.5
Pressing in ball bearing

Fig.6
Pressing on magnetic coupling belt pulley

Note:

Place compressor down flat, otherwise there is a danger that the belt pulley will be deformed when pressing on.

Drive in threaded bush -1-.

Fig.7
Checking and adjusting clearance

Using a depth gauge check clearance while repeatedly switching the magnetic coupling on and off (applying a voltage of 12 V).

Specification: 0.4...0.8 mm

Adjust clearance using shims if necessary. Pull off coupling plate to do this.

Notes:

The clearance must lie within the permitted tolerances over the complete circumference.
The clearance can be measured when the compressor is installed.
If the clearance is outside the specification, remove coupling plate and adjust clearance by removing or installing spacers.