Volkswagen New Beetle. Manual - part 2016

 

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Volkswagen New Beetle. Manual - part 2016

 

 

Fig. 44: Identifying Components Of A/C Clutch -N25- (Sanden)
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

1. Hex nut 

z

Self-locking  

z

Always replace  

z

15 N.m (11 ft. lb)  

z

Removing and installing, See Hex nut, removing and installing  

2. Clutch plate 

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Removing, See A/C clutch -N25-, removing and installing  

z

Checking clutch plate gap, See Clutch plate gap, checking  

3. Shims 

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Used to adjust gap between clutch plate and pulley  

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Gap: 0.4-0.8 mm (0.015-0.023 in)  

4. Circlip 

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Always replace 

„

Install correctly: Flat side faces compressor.  

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Ensure correct seating in groove  

5. Clutch pulley 

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Removing, See Clutch pulley, removing  

6. Circlip 

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Replacing 

„

Install correctly: Flat side faces compressor  

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Ensure correct seating in groove  

7. Clutch coil 

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Installing, See Clutch coil, installing  

8. Connector clip 

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With screw  

9. Harness clip  

10. Harness clip  

11. Screw  

12. Compressor  

NOTE:

The following list refers to items in Fig. 44 .

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.

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

13. Threaded bushing  

A/C CLUTCH -N25-, REMOVING AND INSTALLING 

Special tools, testers, measuring instruments and auxiliary items required 

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Tool 3212 A (or equivalent)  

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Two arm puller  

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Three arm puller  

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Depth gauge  

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Torque wrench (5-50 N.m)  

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

Fig. 45: Identifying Special Tool 3212 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Notes 

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It is not necessary to discharge the refrigerant system to remove and install the A/C clutch.  

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If A/C clutch is to be removed with compressor installed, first do the following: 

{

Remove ribbed belt. See RIBBED BELT, REMOVING AND INSTALLING .  

{

Remove intercooler (engine code ALH only). See CHARGE AIR COOLER COMPONENTS, 
REMOVING AND IN
 .  

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

z

If A/C clutch is to be removed with compressor removed, first discharge refrigerant system. See A/C 
refrigerant system, discharging
 .  

Hex nut, removing and installing 

Fig. 46: Removing And Installing Clutch Plate Hex Nut 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Tightening torque: 15 N.m (11 ft. lb) 

{

Remove hex nut while counter-holding with 3213A or equivalent commercially available 2 hole 
pin wrench (with 4 mm pins).  

Clutch plate, removing 

z

Carefully pry off clutch plate using two large screwdrivers -A-. 

Use locally available 2 or 3 arm puller if plate is securely seated (difficult to remove). 

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

 

 

 

 

 

 

 

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