MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY [FULL-AUTO AIR CONDITIONER]

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*1: Applied VIN (assumed)
European (L.H.D. U.K.) specs.
•  JMZ DE1452*# 400001—471225
•  JMZ DE1455*# 400001—471225
•  JMZ DE14K2*# 400001—471225
•  JMZ DEA452*# 400001—471268
•  JMZ DEA455*# 400001—471268
•  JMZ DEA4J2*# 400001—471268
•  JMZ DEA4K2*# 400001—471268
•  JMZ DEA352*# 300001—306800
•  JMZ DEA3J2*# 300001—306800
•  JMZ DEA3K2*# 300001—306800
General (L.H.D.) specs.
•  JM7 DE10J2*0 200001—223093
•  JM7 DE10Y2*0 200001—223093
General (R.H.D.) specs. (Australia)
•  JM0 DE10Y2*0 200001—223093
General (R.H.D.) specs. (Except Australia)
•  JM6 DE10J2*0 200001—223093
•  JM6 DE10Y2*0 200001—223093
*2: Applied VIN (assumed)
European (L.H.D. U.K.) specs.
•  JMZ DE1452*# 471226—
•  JMZ DE1455*# 471226—
•  JMZ DE14K2*# 471226—
•  JMZ DEA452*# 471269—
•  JMZ DEA455*# 471269—
•  JMZ DEA4J2*# 471269—
•  JMZ DEA4K2*# 471269—
•  JMZ DEA352*# 306801—
•  JMZ DEA3J2*# 306801—
•  JMZ DEA3K2*# 306801—
General (L.H.D.) specs.
•  JM7 DE10J2*0 223094—
•  JM7 DE10Y2*0 223094—
General (R.H.D.) specs. (Australia)
•  JM0 DE10Y2*0 223094—
General (R.H.D.) specs. (Except Australia)
•  JM6 DE10J2*0 223094—
•  JM6 DE10Y2*0 223094—

1.  Assemble in the reverse order of disassembly.

MZR 1.3, MZR 1.5 (Type A)*1

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1
Bolt
(See Bolt Removal/Installation Note (MZR 1.3, MZR 1.5 (Type A)*1).)
2
Pressure plate
3
Shim
4
Snap ring (1)
(See Snap Ring (1) Installation Note.)
5
A/C compressor pulley
6
Screw
7
Clamp
(See Clamp Installation Note.)
8
Snap ring (2)
(See Snap Ring (2) Installation Note.)
9
Stator and thermal protector
(See Stator and Thermal Protector Removal Note.)
(See Stator and Thermal Protector Installation Note.)
10
A/C compressor body

MZR 1.3, MZR 1.5 (Type B)*2

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1
Bolt
(See Bolt Removal/Installation Note (MZR 1.3, MZR 1.5 (Type B)*2).)
2
Washer
3
Pressure plate
4
Shim
5
Snap ring (1)
(See Snap Ring (1) Installation Note.)
6
A/C compressor pulley
(See A/C Compressor Pulley Removal Note (MZR 1.3, MZR 1.5 (Type B)*2).)
(See A/C Compressor Pulley Installation Note (MZR 1.3, MZR 1.5 (Type B)*2).)
7
Snap ring (2)
(See Snap Ring (2) Installation Note.)
8
Stator
9
A/C compressor body

MZ-CD 1.6

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1
Nut
(See Nut Removal/Installation Note.)
2
Pressure plate
3
Shim
4
Snap ring (1)
(See Snap Ring (1) Installation Note.)
5
A/C compressor pulley
6
Snap ring (2)
(See Snap Ring (2) Installation Note.)
7
Stator
(See Stator and Thermal Protector Removal Note.)
(See Stator and Thermal Protector Installation Note.)
8
A/C compressor body

2.  Assemble in the reverse order of disassembly.

3.  Adjust the magnetic clutch clearance. (See MAGNETIC CLUTCH ADJUSTMENT [FULL-AUTO AIR CONDITIONER].)


Bolt Removal/Installation Note (MZR 1.3, MZR 1.5 (Type A)*1)

1.  When removing or installing the bolt, hold the pressure plate in place as shown in the figure.

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2.  When installing a new A/C compressor body, replace the bolt.


Bolt Removal/Installation Note (MZR 1.3, MZR 1.5 (Type B)*2)

1.  When removing or installing the bolt, lock A/C compressor pulley against rotation using the following procedure.

Caution
•  When connecting the positive battery cable to magnetic clutch connector, use a cable with a female terminal of the correct size. Otherwise, load will be applied to the male terminal, resulting in deformation or damage, and poor contact. In addition, the positive battery cable could disconnect from the connector resulting in a short circuit.
(1)  Apply battery positive voltage to the magnetic clutch terminal and connect the A/C compressor body to the ground.
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(2)  Wrap the drive belt, which is no longer of use, tightly around the A/C compressor pulley.
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(3)  Hold the drive belt in place with pliers.
(4)  Remove or install the bolt.
(5)  When installing a new A/C compressor body, replace the bolt.


Nut Removal/Installation Note

1.  When removing or installing the nut, lock A/C compressor pulley against rotation using the following procedure.

Caution
•  When connecting the positive battery cable to magnetic clutch connector, use a cable with a female terminal of the correct size. Otherwise, load will be applied to the male terminal, resulting in deformation or damage, and poor contact. In addition, the positive battery cable could disconnect from the connector resulting in a short circuit.
(1)  Apply battery positive voltage to the magnetic clutch terminal and connect the A/C compressor body to the ground.
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(2)  Wrap the drive belt, which is no longer of use, tightly around the A/C compressor pulley.
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(3)  Hold the drive belt in place with pliers.
(4)  Remove or install the nut.
(5)  When installing a new A/C compressor body, replace the nut.


Stator and Thermal Protector Removal Note

1.  After removing the stator and thermal protector, completely remove the silicone adhering to the A/C compressor side.


Stator and Thermal Protector Installation Note

1.  Apply approx. 1 g {0.04 oz} of silicone (Shin-Etsu Silicone KE-347W or similar) to the contact surface of the thermal protector, then thoroughly install it onto the A/C compressor, leaving no gaps.

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Snap Ring (2) Installation Note

1.  When installing a stator and thermal protector, replace the snap ring (2).

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Clamp Installation Note

1.  When installing a new stator and thermal protector, replace the clamp.


Snap Ring (1) Installation Note

1.  When installing a new pressure plate, A/C compressor pulley, stator, or A/C compressor body, replace the snap ring (1).

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A/C Compressor Pulley Removal Note (MZR 1.3, MZR 1.5 (Type B)*2)

1.  Remove the A/C compressor pulley using the SST (49 0839 425C, 49 U027 001).

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Caution
•  Be careful that the SST (49 0839 425C) tabs do not hang over the stator.
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Note
•  Place on the tape to prevent damage.


A/C Compressor Pulley Installation Note (MZR 1.3, MZR 1.5 (Type B)*2)

1.  Set the SSTs (49 0829 425C (HEAD), 49 B018 003) as shown in the figure.

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2.  Insert the compressor pulley to the position shown in the figure using the SSTs (49 0829 425C (HEAD), 49 B018 003) and a plastic hammer.

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Caution
•  If the SST is not properly positioned when the A/C compressor pulley is press-fit, the A/C compressor axle will interfere with the SST, possibly damaging component parts. Verify that the SST and axle are properly positioned and perform the procedure very carefully.
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3.  Set the SSTs (49 0829 425C (HEAD), 49 B018 003) as shown in the figure.

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4.  Insert the compressor pulley using the SSTs (49 0829 425C (HEAD), 49 B018 003) and a plastic hammer.

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