R-134A System

A/C Clutch (N25), Assembly







Note: Illustration at left shows the Sanden model SD7 H15 compressor which is not used on Passat vehicles; however, the correct A/C clutch assembly information is shown.

1 - Nut (self locking)
- removing, see Fig. 1
- gap between clutch plate and belt pulley, adjusting, see Fig.1
- gap between clutch plate and belt pulley, measuring, see Fig. 2
2 - Clutch plate
- removing, see Fig. 3
3 - Lock ring
4 - Belt pulley
- removing, see Fig. 4
- installing, see Fig. 5
5 - Bearing assembly
- removing, see Fig. 6
- installing, see Fig. 7
6 - Snap ring
7 - Snap ring
8 - A/C Clutch coil
9 - Key
10 - A/C compressor
- refrigerant oil capacity: 115 cc (3.9 oz)





Fig. 1 - Clutch plate nut, removing/installing and gap between clutch plate and belt pulley, adjusting

- hold clutch plate using spanner wrench -A- (Mastercool tool No.90901 or equivalent) and remove clutch plate nut

A - Mastercool tool No. 90901 or equivalent
B - Hex head bolt, 1/4 in. (for tool)

To adjust gap between clutch plate and belt pulley,
- hold clutch plate and tighten clutch plate nut (self-locking) until gap -a- = 0.7 mm (0.028 in. or approx. 1/32 in.)





Fig. 2 - Gap between clutch plate and belt pulley, measuring

- measure distance between clutch plate and belt pulley as shown
- using a fused 12 Volt power supply, connect 12 V (power (B+) and Ground) to A/C clutch connector
- with clutch engaged, measure distance between clutch plate and belt pulley once again

- difference between first and second measurement is gap
- must be 0.7 mm (0.028 in. or approx. 1/32 in.)

- to adjust gap, see Fig. 1





Fig.3 - Clutch plate, removing

- remove front clutch plate using clutch plate puller -1- (Mastercool tool No. 90902 or equivalent - similar tool shown) and 1/4 in. bolts -2-





Fig.4 - Belt pulley, removing

- using puller US 1078 or equivalent, remove belt pulley




Fig. 5 - Belt pulley, installing

- using thrust plates VW 401 and VW402 and thrust bushings VW 412 and VW 441 press belt pulley onto shaft





Fig. 6 - Bearing assembly, removing

- using thrust plates VW 401 and VW 402, thrust bushing VW 412 and thrust tube VW 455, press bearing from pulley





Fig. 7 - Bearing assembly, installing

- using thrust plates VW 401 and VW 402 and thrust bushings VW 412 and VW 473, press bearing onto pulley until fully seated