Concerning 2007 and later Suzuki models: if the A/C does not cool, when diagnosing the problem you may determine that the compressor clutch does not engage when power is applied.

The cause is an open circuit in the electromagnet. 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 refrigerant from the system to perform this repair.

Clutch P/N….95211-80JA0

Clip kit P/N…95212-58JA0

NOTE: Do not replace the compressor when there is a clutch failure, unless the compressor was damaged as a result of the clutch failure.

NOTE: The clip kit includes extra shims. These are only necessary if shims are required for gap adjustment or if the C-clip is broken.

PROCEDURE

Access is via the right front wheel well area.

Access is via the right front wheel well area.

1. Securely place the vehicle on a lift and raise the vehicle enough to access the right front undercover. Remove the undercover (you may also wish to remove the right front wheel assembly).

 2. Release the tension from the serpentine belt and slide the belt off of the compressor pulley.

Remove the serpentine belt from the compressor pulley.

Remove the serpentine belt from the compressor pulley.

3. Disconnect the electrical connector to the clutch magnet and remove the four compressor mounting bolts.

Electrical connector and two mounting bolts shown here.

Electrical connector and two mounting bolts shown here.

 

4. 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. Do not lose the shims. A ratchet wrench and three-point spanner may be used.

5. With the compressor in a suitable position, remove the circlip with a 45 degree angle circlip tool.

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Use a 45-degree circlip tool to remove the pulley clip.

Use a 45-degree circlip tool to remove the pulley clip.

 

6. Rock the clutch pulley equally from both sides and work it off of the compressor stationary shaft.

 7. Using a straight circlip tool, remove the circlip from the clutch magnet and remove the magnet.

Use a straight circlip tool to remove the clip from the clutch magnet.

Use a straight circlip tool to remove the clip from the clutch magnet.

 

8. 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.

When installing the new clutch magnet, be sure to align the dimple in the compressor groove.

When installing the new clutch magnet, be sure to align the dimple in the compressor groove.

 

9. Hold the compressor and magnet with your right hand and install the circlip with your left hand, using a 45 degree circlip tool. Note that the circlip rounded side faces the compressor.

When installing the magnet circlip, the rounded side of the clip must face the compressor.

When installing the magnet circlip, the rounded side of the clip must face the compressor.

 

10. Re-install the clutch pulley.

 11. Insert the mounting bolt into the armature plate, and then place the shims onto the bolt before installing to the compressor.

Place shims onto the armature bolt before installing to the compressor.

Place shims onto the armature bolt before installing to the compressor.

 

 12.  Install the plate to the compressor, tightening the bolt to 11.5 ft-lb (16 Nm).

 13. Check the armature to clutch pulley gap with a feeler gauge. Rotate the armature plate and check at several points. The gap should be within 0.012-0.020 in. (0.3-0.5mm). If not within spec, remove the plate and install or remove the appropriate thickness shim(s).

Check armature-to-clutch-pulley gap at several points.

Check armature-to-clutch-pulley gap at several points.

 

14. Re-connect the electrical connector to the clutch magnet.

15. Re-mount the compressor to the engine. Tighten the mounting bolts to a value of 18.0 ft-lb (25 Nm).

16. Lower the vehicle and test the A/C for operation. If OK, re-install the undercover and right front wheel assembly.

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