Mazda 2: Magnetic Clutch

MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY

1. Assemble in the reverse order of disassembly.

1. Bolt
2. Washer
3. Pressure plate
4. Shim
5. Snap ring (1)
6. A/C compressor pulley
7. Snap ring (2)
8. Stator
9. A/C compressor body

2. Assemble in the reverse order of disassembly.

3. Adjust the magnetic clutch clearance. (See MAGNETIC CLUTCH ADJUSTMENT [MANUAL 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 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.

a. Apply battery positive voltage to the magnetic clutch terminal and connect the A/C compressor body to the ground.

b. Wrap the drive belt, which is no longer of use, tightly around the A/C compressor pulley.

c. Hold the drive belt in place with pliers.

d. Remove or install the bolt.

Tightening torque

• 17-19 N*m {1.8-1.9 kgf*m, 13-14 ft*lbf}

A/C Compressor Pulley Removal Note

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

CAUTION:

• Be careful that the SST (49 0839 425C) tabs do not hang over the stator.

NOTE:

• Place on the tape to prevent damage.

A/C Compressor Pulley Installation Note

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

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.

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.

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

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

Snap Ring (2) Installation Note

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

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).

Shim Installation Note

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

MAGNETIC CLUTCH ADJUSTMENT

1. Measure the clearance around the entire circumference between the pressure plate and A/C compressor pulley using a thickness gauge.

2. Verify that the clearance is within the specification.

• If not within the specification, remove the pressure plate and adjust the clearance by changing the shim (0.2 mm {0.008 in}, 0.5 mm {0.02 in}) or the number of shims.

Magnetic clutch clearance

• 0.3-0.6 mm {0.012-0.023 in}

MAGNETIC CLUTCH INSPECTION

1. Connect battery positive voltage to terminal A of magnetic clutch and ground to A/C compressor body.

2. Verify that the magnetic clutch operates.

• If there is any malfunction, replace the stator and thermal protector.

EVAPORATOR TEMPERATURE SENSOR REMOVAL/INSTALLATION

1. Remove the evaporator temperature sensor from the A/C unit. (See A/C UNIT DISASSEMBLY/ASSEMBLY).

EVAPORATOR TEMPERATURE SENSOR INSPECTION

1. Set the fan speed MAX HI.

2. Set the temperature control at MAX COLD (Turn left).

3. Set the RECIRCULATE mode.

4. Turn the A/C switch off.

5. Close all doors and windows.

6. Wait for 5 min.

7. Disconnect the evaporator temperature sensor connector.

8. Measure the temperature at the blower inlet.

9. Measure the resistance between terminals of the evaporator temperature sensor.

• If the resistance is not as shown in the graph, replace the evaporator temperature sensor.

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