Servicing magnetic coupling -N25- with compressor removed; Sanden — VW

Required special tools, workshop equipment, test and measuring devices and aids

3212 Pin-type face spanner
VW 401 Thrust plate
VW 402 Thrust plate
VW 412 Pressure plunger
VW 432 Thrust piece
VW 441 Mounting

Not shown:

Commercially available two-arm puller, e.g. Kukko 20-10 with hooks with
100 mm clamping depth.
Depth gauge

V.A.G 1616 Brace for coupling pulley

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

Please carry out the following work first:

Evacuate refrigerant with service station V.A.G 1885.

Note:

It is punishable by law to drain off refrigerant into the environment.

Remove A/C compressor from bracket
=> Removing and installing A/C compressor bracket.

Hexagon nut
Self-locking
Renew
20 Nm
Unscrewing =>Fig.
1

Coupling pulley
Pulling off =>Fig.
2
Checking gap dimension =>Fig.
7

Circlip
Renew

Install facing proper direction:
Flat side faces compressor

Ensure proper seating in groove

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

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

Circlip
Renew

Install facing proper direction:
Flat side faces compressor

Ensure proper seating in groove

Circlip
Renew

Install facing proper direction:
Flat side faces compressor

Ensure proper seating in groove

Magnetic coil
Locking with dowel pin
Mounting with circlip -
7
-

Note:

An overheating fuse is integrated in the magnetic coil. The overheating fuse interrupts the magnetic coil as soon as (for example, due to a sticky compressor) the magnetic coupling becomes too hot.

Shims
For adjusting gap dimension between coupling and belt pullies
Checking gap dimension =>Fig.
7

Wedge
Compressor
Manufacturer: Sanden
Table of compressor manufacturers: => page
87-61

Removing magnetic coupling from compressor and mounting again

Fig.1
Unscrewing hexagon nut

Unscrew hexagon nut with brace for coupling pulley 3212 or V.A.G 1616.

Fig.2
Pulling off coupling pulley

Note:

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

Fig.3
Pulling off belt pulley e for magnetic coupling

Position hooks -arrow- as shown in illustration.

Note:

If the okk is positioned on the lower edge of the belt pulley, there is a danger that the coil of the magnetic coupling -N25- will be damaged.

Pull off belt pulley with commercially available, e.g. Kukko 20-10 with hooks with 100 mm clamping depth.

Fig.4
Pressing off ball bearing

Fig.5
Pressing in ball bearing

Fig.6
Pressing on belt pulley for magnetic coupling

Note:

Lay on the compressor flat, as otherwise there is a danger that the belt pulley will be deformed when it is pressed on.

Drive back threaded sleeve -1-.

Fig.7
Checking and adjusting gap dimension

Measure gap dimension with depth gauge while repeatedly switching magnetic coupling on and off (connect voltage of 12 V).

Specified value: 0.4 - 0.8 mm

Adjust the gap with shims if necessary. Pully off the coupling disk to do so.

Note:

The gap dimension must be within the specified tolerance around the entire circumference.
The gap dimension can also be measured with the compressor installed.
If the gap dimension is outside the specified value, remove the coupling pulley and adjust the gap dimension by removing or inserting shims.