Suzuki Grand Vitara JB416 / JB420. Manual - part 297

7B-79 Air Conditioning System: 

Magnet Clutch Removal and Installation for M16 
Engine Model

S5JB0A7206048

Removal

1) Remove compressor from vehicle. Refer to 

“Compressor Assembly Removal and Installation for 
M16 Engine Model”.

2) Fix armature plate (1) with special tool (A) and 

remove armature plate bolt (2).

Special tool
(A):  09991–06310

NOTE
Do not reuse armature plate bolt.

 

3) Remove armature plate.
4) Remove shims from shaft.
5) Using special tool (A), remove circlip (1).

Special tool
(A):  09900–06107

6) Remove magnet clutch lead wire clamp screw, and 

remove magnet clutch read wire ground terminal.

7) Remove magnet clutch pulley with puller (1).

NOTE
Be careful not to damage pulley when 
tapping magnet clutch.

 

8) Remove magnet clutch bolts, and then remove 

magnet clutch coil.

NOTE
Do not reuse magnet clutch bolts.

 

Installation

1) Install magnet clutch coil (2), and then tighten new 

magnet clutch coil bolts (1) as specified torque.

Tightening torque
Magnet clutch coil bolt (a):  4.9 N·m (0.49 kgf-m, 
4.0 lb-ft)

1

2

(A)

I5JB0A720064-02

(A)

1

I5JB0A720065-01

2. Compressor

1

2

I5JB0A720066-01

2

1, (a)

I5JB0A720067-02

Air Conditioning System:  7B-80

2) Install clamp portion and ground terminal of lead 

wire.

3) Install magnet clutch pulley (1).

a) Set magnet clutch squarely over clutch 

installation boss.

b) Place special tool (A) onto clutch bearing.

Ensure that edge rests only on inner race of 
bearing.

Special tool
(A):  09951–15510

c) Install snap ring (1) using special tool (B).

Special tool
(B):  09900–06107

CAUTION

!

 

Be careful not to scratch bearing seal.

 

4) Inspect clearance between armature plate (1) and 

magnet clutch pulley as follows.
a) Put compressor in a vise (2).
b) Set dial gauge (3) on armature plate, and then 

adjust its pointer at 0.

c) Connect battery positive terminal (+) to magnet 

clutch coil lead wire.

d) Connect battery negative terminal (–) to 

compressor body assembly. (At this point, 
armature plate and magnet clutch pulley are kept 
in contact.)

e) Disconnect battery negative terminal (–) to 

compressor body assembly. (At this point, 
armature plate and magnet clutch pulley are not 
in contact.)

f) Read stroke of armature plate from dial gauge by 

performing Step d) and e) repeatedly. (Stroke of 
armature plate is clearance between armature 
plate and magnet clutch pulley.)
If clearance is out of specification, adjust 
clearance by changing number and/or thickness 
of shim(s).

Standard clearance between armature plate and 
magnet clutch
“a”: 0.3 – 0.5 mm (0.012 – 0.020 in.)

5) Tighten new armature plate bolt (1) as specified 

torque.

Tightening torque
Armature plate bolt (a):  15 N·m (1.5 kgf-m, 11.0 
lb-ft)

Special tool
(A):  09991–06310

1

(A)

I5JB0A720068-02

(B)

1

1

I5JB0A720087-02

2. Armature plate

1

2

1

3

“a”

I5JB0A720069-01

2

1

(A)

I5JB0A720070-02

7B-81 Air Conditioning System: 

Magnet Clutch Removal and Installation for J20 
Engine Model

S5JB0A7206049

Removal

1) Remove compressor from vehicle referring to 

“Compressor Assembly Removal and Installation for 
J20 Engine Model”.

2) Fix armature plate (1) with special tool (A) and 

remove armature plate bolt.

Special tool
(A):  09991–06310

NOTE
Do not reuse armature plate bolt.

 

3) Remove armature plate.
4) Remove shim(s) from shaft.
5) Using special tool (A), remove snap ring (1).

Special tool
(A):  09900–06107

6) Remove magnet clutch pulley (1) with puller (2).

NOTE
Be careful not to damage pulley.

 

7) Remove snap ring (1) using special tool (B), and 

then remove magnet clutch coil (1).

Special tool
(A):  09900–06107

Installation

1) Install magnet clutch coil (3).

NOTE
Protrusion (1) on underside of magnet clutch 
coil and hole (2) on compressor body 
assembly must match to stop movement of 
magnet clutch coil and to locate lead wire 
correctly.

 

1

(A)

2

I5JB0A720071-01

(A)

1

I5JB0A720072-01

1

2

I5JB0A720073-01

(A)

1

I5JB0A720074-02

2

1

3

I5JB0A720075-01

Air Conditioning System:  7B-82

2) Install new snap ring (1) using special tool (A).

Special tool
(B):  09900–06107

3) Install magnet clutch pulley.

a) Set magnet clutch horizontally over clutch 

installation boss.

b) Place special tool (B) onto magnet clutch 

bearing. Ensure that edge rests only inner rase 
of bearing.

Special tool
(B):  09951–15510

c) Install new snap ring (1) using special tool (A).

Special tool
(A):  09900–06107

4) Install armature plate (1).
5) Using special tool (A), tighten new armature plate 

bolt (2) to specified torque.

Tightening torque
Armature plate bolt (a):  21 N·m (2.1 kgf-m, 15.5 
lb-ft)

Special tool
(A):  09991–06310

6) Adjust clearance between armature plate (1) and 

magnet clutch pulley by putting shim(s) on 
compressor shaft. To measure the clearance, 
perform the following steps.
a) Put compressor in a vise.
b) Set dial gauge on magnet clutch plate, and then 

adjust its pointer at 0.

c) Connect battery positive terminal (+) to magnet 

clutch coil lead wire.

d) Connect battery negative terminal (–) to 

compressor body assembly. (At this point, 
armature plate and magnet clutch pulley (2) are 
kept in contact.)

e) Disconnect battery negative terminal (–) to 

compressor body assembly. (At this point, 
armature plate and magnet clutch pulley (2) are 
not in contact.)

f) Read stroke of armature plate from dial gauge by 

performing Step d) and e) repeatedly. (Stroke of 
armature plate is clearance between armature 
plate and magnet clutch pulley (2).)

Standard clearance between armature plate and 
magnet clutch
“a”: 0.3 – 0.6 mm (0.012 – 0.024 in.)

7) Install compressor to vehicle referring to 

“Compressor Assembly Removal and Installation for 
J20 Engine Model”.

(A)

1

1

I5JB0A720088-04

(B)

I5JB0A720076-02

(A)

1

1

I5JB0A720077-01

1

2

2

1

“a”

I5JB0A720078-02