Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and aux. 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.
• ◆ Depth gauge

• ◆ → 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.

Notes:

Releasing refrigerant into the environment is a punishable offence.

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

• Hexagon nut
• ◆ Self-locking
• ◆ Replacing
• ◆ 20 Nm
• ◆ 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

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

• ‒ Check clearance with a depth gauge by 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.