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

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MZR 1.8, MZR 2.0, MZR 2.0 DISI, MZR 2.5

1.  Disassemble in the order indicated in the table.

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1
Bolt
(See Bolt removal/installation note.)
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
Screw
7
Stator
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

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
•  20—22 N·m {2.1—2.2 kgf·m, 15—16 ft·lbf}


Snap ring removal/installation note

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

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A/C compressor pulley removal note

1.  Remove the A/C compressor pulley using the SSTs (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
•  Taping on the nail for protect to damage.


A/C compressor pulley installation note

1.  Install the inner wheel of the pulley using a press and SST (49 B034 212) to the compressor.

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.
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Shim installation note

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

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MZR-CD 2.2

1.  Disassemble in the order indicated in the table.

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1
Bolt
(See Bolt removal/installation note.)
2
Pressure plate
3
Shim
4
Snap ring
(See Snap ring installation note.)
5
A/C compressor pulley
6
Clamp
(See Clamp installation note.)
7
Screw
(See Screw installation note.)
8
Screw
9
Stator and thermal protector
(See Thermal protector removal note.)
(See 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

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 recommended bolt.


Thermal protector removal note

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


Thermal protector installation note

1.  Apply approx. 1g {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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Screw installation note

1.  When installing a new thermal protector, replace the screw.


Clamp installation note

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


Snap ring installation note

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

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