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

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1.  Disassemble in the order indicated in the table.

SKYACTIV-G 2.0

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1
Bolt
(See Bolt Removal/Installation Note (SKYACTIV-G 2.0, MZR 2.0, MZR 2.0 DISI i-stop, MZR 2.3 DISI Turbo, MZR 2.5).)
2
Pressure plate
3
Shim
(See Shim Installation Note.)
4
Snap ring
(See Snap Ring Removal/Installation Note.)
5
A/C compressor pulley
6
Snap ring
(See Snap Ring Removal/Installation Note.)
7
Stator
8
A/C compressor body

MZR 2.5, MZR 2.3 DISI Turbo

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1
Bolt
(See Bolt Removal/Installation Note (SKYACTIV-G 2.0, MZR 2.0, MZR 2.0 DISI i-stop, MZR 2.3 DISI Turbo, MZR 2.5).)
2
Pressure plate
3
Shim
(See Shim Installation Note.)
4
Snap ring
(See Snap Ring Removal/Installation Note.)
5
A/C compressor pulley
(See A/C Compressor Pulley Removal Note.)
(See A/C Compressor Pulley Installation Note.)
6
Snap ring
(See Snap Ring Removal/Installation Note.)
7
Stator
8
A/C compressor body

MZR 2.0, MZR 2.0 DISI i-stop

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1
Bolt
(See Bolt Removal/Installation Note (SKYACTIV-G 2.0, MZR 2.0, MZR 2.0 DISI i-stop, MZR 2.3 DISI Turbo, MZR 2.5).)
2
Pressure plate
3
Shim
(See Shim Installation Note.)
4
Snap ring
(See Snap Ring Removal/Installation Note.)
5
A/C compressor pulley
(See A/C Compressor Pulley Removal Note.)
(See A/C Compressor Pulley Installation Note.)
6
Snap ring
(See Snap Ring Removal/Installation Note.)
7
Stator
8
A/C compressor body

MZR 1.5, MZR 1.6

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1
Bolt
(See Bolt Removal/Installation Note (MZR 1.5, MZR 1.6, MZR-CD 2.2).)
2
Pressure plate
3
Shim
(See Shim Installation Note.)
4
Snap ring
(See Snap Ring Removal/Installation Note.)
5
A/C compressor pulley
6
Screw
(See Screw Installation Note.)
7
Clamp
(See Clamp Installation Note.)
8
Screw
(See Screw 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

MZ-CD 1.6

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1
Nut
(See Nut Removal/Installation Note (MZ-CD 1.6).)
2
Pressure plate
3
Shim
(See Shim Installation Note.)
4
Snap ring
(See Snap Ring Removal/Installation Note.)
5
A/C compressor pulley
6
Snap ring
(See Snap Ring Removal/Installation Note.)
7
Stator
8
O-ring
9
Bolt
10
Bracket
11
A/C compressor body

MZR-CD 2.2

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1
Bolt
(See Bolt Removal/Installation Note (MZR 1.5, MZR 1.6, MZR-CD 2.2).)
2
Pressure plate
3
Shim
(See Shim Installation Note.)
4
Snap ring
(See Snap Ring Removal/Installation Note.)
5
A/C compressor pulley
6
Clamp
(See Clamp Installation Note.)
7
Screw
(See Screw Installation Note.)
8
Screw
(See Screw 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

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 1.5, MZR 1.6, MZR-CD 2.2)

Note
•  If there are only 2 prepackaged bolts available when replacing the compression with a repair part, select bolts from the replaced unit of the same length as the prepackaged bolts.

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

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Tightening torque
13.7—15.7 N·m {1.4 —1.6 kgf·m, 9.4 — 11.5 ft·lbf}

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


Bolt Removal/Installation Note (SKYACTIV-G 2.0, MZR 2.0, MZR 2.0 DISI i-stop, MZR 2.3 DISI Turbo, MZR 2.5)

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

Caution
•  When connecting the positive battery cable to the magnetic clutch connector, use a cable with a female terminal of the correct size. Otherwise, load will be applied to the 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/installation the bolt.
Tightening torque
13.7—15.7 N·m {1.4 —1.6 kgf·m, 9.4 — 11.5 ft·lbf}

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


Nut Removal/Installation Note (MZ-CD 1.6)

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

Caution
•  When connecting the positive battery cable to the magnetic clutch connector, use a cable with a female terminal of the correct size. Otherwise, load will be applied to the 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/installation the nut.
Tightening torque
26—30 N·m {2.7 —3.0 kgf·m, 20 — 22 ft·lbf}

2.  When installing a new A/C compressor body, replace the recommended 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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A/C Compressor Pulley Removal Note

Note
•  It may be difficult to remove the A/C compressor pulley due to the differences in the inner diameter tolerance. If the A/C compressor pulley cannot be removed even after pulling it, remove the pulley using the following procedure.

1.  Remove the A/C compressor pulley using the SSTs (49 0839 425C, 49 SE01 160).

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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

1.  Install the inner wheel of the pulley using SST (49 D034 202) to the compressor.

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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 the SST and axle are properly positioned and perform the procedure very carefully.

Snap Ring Removal/Installation Note

1.  Remove/install the snap ring using a snap ring pliers.

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Screw Installation Note

1.  When installing a new stator, replace the screw.


O-ring Installation Note

1.  When installing a new oil plug, replace the O-ring.


Clamp Installation Note

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


Shim Installation Note

1.  First, insert the 1mm (0.039 in) thick shim into the shaft.

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