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How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch

  1. How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch, Identifying the problem: шаг 1, изображение 1 из 2 How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch, Identifying the problem: шаг 1, изображение 2 из 2
    • The aircondition is under normal conditions not running permanently, but it is running in intervals, e.g. on for 10s and then off for a similar amount of time.

    • On colder days, the 'on' period will be relatively shorter. On hot days, the 'on' period will be relatively longer - ultimately permanently on.

  2. How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch, The magnetic clutch and the fan: шаг 2, изображение 1 из 3 How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch, The magnetic clutch and the fan: шаг 2, изображение 2 из 3 How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch, The magnetic clutch and the fan: шаг 2, изображение 3 из 3
    • When the aircon computer signals 'on', the magnetic clutch will engage and thereby activate the aircon compressor.

    • Whenever the magnetic clutch is engaged, the cooling fan is also activated (at least on my Mazda)

    • When leaving my the car in idle for around 15 minutes, the aircon suddenly stops working:

    • The magnetic clutch stops engaging, though the computer is telling it to activate (see oscilloscope dump)

    • The cooling fan is permanently on, suggesting that the clutch should also be engaged, which it obviously is not.

    • Stopping the car, and letting it cool down for a while (30 minutes?) will normally make the magnetic clutch engage again.

  3. How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch, Testing the hypothesis: шаг 3, изображение 1 из 2 How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch, Testing the hypothesis: шаг 3, изображение 2 из 2
    • So the suspission is, that the clutch is actually activated by the aircon computer, but for some reason the clutch is unable to engage.

    • By turning front wheels, it is possible to partly see the magnetic clutch (it is in the red circle on the photo).

    • With a small stick (I used a bamboo stick) I can carefully, but firmly, poke the clutch, and thereby helping it to engage. Be careful - there are a lot of moving parts in there...

    • Shortly after the clutch is engaged and cooling is ongoing, the aircon computer will release the clutch again (like during normal operation)

    • Next time the aircon computer tries to engage the clutch, it will fail. Again it is necessary to poke it with the stick, to make it engage.

    • The above indicates that something is obstructing the normal operation of the magnetic clutch.

  4. How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch, Is the magnetic clutch stuck?: шаг 4, изображение 1 из 2 How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch, Is the magnetic clutch stuck?: шаг 4, изображение 2 из 2
    • The magnetic clutch should apparently be able to move a little when you pull/push it with your hands - mine is completely stuck. This video demonstrates this, and it also demonstrates the "poking with a stick" trick. https://www.youtube.com/watch?v=Hqp9IJ2i...

    • To get better access to the magnetic clutch, lift up the car and remove the right hand front wheel. Place the wheel under the car as a safety precaution.

    • Behind the brake disc you can see a plastic shield that is easily removed to access the clutch

  5. How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch, Getting access to the magnetic clutch: шаг 5, изображение 1 из 3 How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch, Getting access to the magnetic clutch: шаг 5, изображение 2 из 3 How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch, Getting access to the magnetic clutch: шаг 5, изображение 3 из 3
    • Remove the 4-5 screws holding the plastic shield covering the magnetic clutch

    • Unscrew the bolt in the center of the magnetic clutch. You will need to hold a screwdriver like in the picture while you loosen the bolt

  6. How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch: шаг 6, изображение 1 из 3 How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch: шаг 6, изображение 2 из 3 How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch: шаг 6, изображение 3 из 3
    • I am completely unable to move the clutch plate with my fingers. I used some scrap metal pieces to gradually force the plate free.

    • NOTICE: later I discovered that a bolt can actually be fitted (see pictures for the next step)

    • Gently hammer on the clutch plate top and bottom, while carefully forcing scrap metal in behind the clutch plate.

    • Applying some WD40 did not seem to make much difference, but you can give it a try.

  7. How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch: шаг 7, изображение 1 из 2 How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch: шаг 7, изображение 2 из 2
    • Though it took a bit of brute force to get the plate free, it did not suffer any visible damage. You can barely see the shims inside - be careful not to loose them.

    • It was only after I got the plate loosened, that I noticed that it is actually threaded to allow a bolt being screwed in. This could probably have been handy when loosening the clutch plate.

  8. How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch: шаг 8, изображение 1 из 2 How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch: шаг 8, изображение 2 из 2
    • Be careful to get the shims out, so they are not accidentally lost. My clutch had 2 shims.

    • Inside the clutch plate, I could see bits of green/corroded debris.

  9. How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch: шаг 9, изображение 1 из 3 How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch: шаг 9, изображение 2 из 3 How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch: шаг 9, изображение 3 из 3
    • Clean out all visible debris from clutch plate and the clutch itself.

  10. How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch: шаг 10, изображение 1 из 1
    • Microscope (4x) view of the debris. I cannot tell where it originates from.

  11. How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch: шаг 11, изображение 1 из 2 How to fix problem with 2010 Mazda 5 (3) air conditioner magnetic clutch: шаг 11, изображение 2 из 2
    • After cleaning everything carefully, I also sanded the two parts a bit, and applied a bit of grease.

    • Verify that the clutch plate can now move back and forth easily.

    • Assemble everything again, and now you can hopefully enjoy a working aircon, that does not stop working while you are driving.

Заключение

To reassemble your device, follow these instructions in reverse order.

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LarsWH

Участник с: 03/05/16

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