Ac Does Not Cool: Compressor Clutch Does Not Engage (TS 01 09267)

Publication date: 2007-09-06
Reference number: TS 01 09267

AC DOES NOT COOL: COMPRESSOR CLUTCH DOES NOT ENGAGE

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 01 09267, Date of Issue: September 26, 2007

SUZUKI:	2007~ SX4 (RW420)
SECTION:	HVAC

CONDITION

Air conditioner does not cool. When diagnosed it is found the compressor clutch does not engage when power is applied.

CAUSE

Open circuit in electromagnet.

CORRECTION

If the electric clutch circuit is found to be open internally at the clutch assembly, replace only the clutch assembly. The clutch is available separately from the compressor. It is not necessary to remove the refrigerant from the system to do this repair. Follow the below procedure to replace the clutch assembly.

PART(S) INFORMATION

Part Numbers	Description	QTY	Notes
95211-80JA0	Clutch	1	DO NOT REPLACE THE COMPRESSOR WHEN THERE IS A CLUTCH FAILURE UNLESS THE COMPRESSOR WAS DAMAGED FROM THE FAILURE.
95212-58JA0	Clip Kit	1	Clip kit includes extra shims. Only necessary if shims are required for gap adjustment or C-clip is broken.

WARRANTY CLAIM INFORMATION

Labor Operation	Description	Failed Part Number	Complaint Code	Defect Code	Labor Time
TB04R0	Magnet Clutch Assembly	95211-80JA0	59	36	1.6 Hrs.

Repair Procedure

Compressor Clutch Replacement Procedure on Vehicle

Securely place the vehicle on a lift and raise the vehicle enough to access the right front under cover. Remove the under cover. (Optionally remove the right front wheel assembly.)

Fig 1: Accessing Right Front Under Cover
Courtesy of SUZUKI OF AMERICA CORP.
Release the tension from the serpentine belt and slide the belt off of the compressor pulley.

Fig 2: Releasing Tension From Serpentine Belt
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect the electrical connector to the clutch magnet and remove the four mounting bolts of the compressor.

Fig 3: Identifying Compressor Mounting Bolts & Connector
Courtesy of SUZUKI OF AMERICA CORP.
At the right wheel well, move the compressor to an angle suitable to remove the front armature plate bolt. Rock the plate and pull to remove plate. Do not lose the shims (See step 11). A ratchet wrench and three point spanner is being used in this example.

Fig 4: Identifying Front Armature Plate Bolt
Courtesy of SUZUKI OF AMERICA CORP.
With the compressor in the position shown, remove the circlip with a 45 degree angle circlip tool.

Fig 5: Removing Circlip
Courtesy of SUZUKI OF AMERICA CORP.
Rock the clutch pulley equally from both sides and work it off the compressor stationary shaft.

Fig 6: Identifying Clutch Pulley
Courtesy of SUZUKI OF AMERICA CORP.
Using a straight circlip tool, remove the circlip from the clutch magnet and remove the magnet.

Fig 7: Removing Circlip From Clutch Magnet
Courtesy of SUZUKI OF AMERICA CORP.
Re-install the new clutch magnet. Note the index marks. The dimple must be aligned in the compressor groove or the clutch will fail when first engaged.

Fig 8: Installing Clutch Magnet
Courtesy of SUZUKI OF AMERICA CORP.
Hold the compressor and magnet with your right hand and install the circlip with your left hand using a 45 degree angle circlip tool. Note circlip rounded side faces compressor.

Fig 9: Installing Circlip
Courtesy of SUZUKI OF AMERICA CORP.
Re-install the clutch pulley.

Fig 10: Installing Clutch Pulley
Courtesy of SUZUKI OF AMERICA CORP.
Insert the mounting bolt into the armature plate then place the shims onto the bolt before installing to compressor.
Install the plate to the compressor. Torque the bolt to 16 Nm (11.5 lb-ft).
Check the armature to clutch pulley gap with a feeler gauge. Rotate the armature plate and check at several points. The gap should within 0.3-0.5 mm (0.012-0.020 in.). If not within spec., remove the plate and install or remove the appropriate thickness shim(s).

Fig 11: Checking Armature To Clutch Pulley Gap

Courtesy of SUZUKI OF AMERICA CORP.

Re-connect the electrical connector to the clutch magnet.
Re-mount the compressor to the engine. Torque the bolt to 25 Nm (18.0 lb-ft).
Lower the vehicle and test the A/C for operation. If OK re-install the under cover and right wheel assembly (if removed).
Repair is complete.