HVAC System: Other Mazda 3 BK

FOREWORD

1. The areas for inspection (steps) are given according to various circuit malfunctions. Use the following chart to verify the symptoms of the trouble in order to diagnose the appropriate area.

Scheme 79

TROUBLESHOOTING CODES

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

1. When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while performing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If there is a problem, inspect to make sure connectors, terminals and wiring harnesses are connected correctly and undamaged.

Scheme 85

Scheme 86

Scheme 87

Scheme 88

NO. 5 WINDSHIELD FOGGED

1. When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If there is a problem, inspect to make sure connectors, terminals and wiring harness are connected correctly and undamaged.

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Handling Refrigerant

1. Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose and throat. Also, due to environmental concerns, we urge use of recovery/recycling/recharging equipment when draining R-134a from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service.
2. Do not perform pressure test or leak test for R-134a service equipment and/or vehicle air conditioning system using compressed air. Some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers.
3. Do not allow the refrigerant to leak near fire or any kind of heat. A poisonous gas may be generated if the refrigerant gas contacts fire or heat such as from cigarettes and heaters. When carrying out any operation that can cause refrigerant leakage, extinguish or remove the above-mentioned heat sources and maintain adequate ventilation.
4. Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostbite. When handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes, immediately wash them with clean water and consult a doctor.

Storing Refrigerant

1. The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Store the refrigerant at temperatures below 40 °C {104 °F}.

Handling Insufficient Refrigerant Level

1. If an insufficient refrigerant level is detected at troubleshooting, do not charge (add) the refrigerant. Because an accurate amount of refrigerant cannot be determined from the pressure indicated on the manifold gauge, never charge the refrigerant. If there is too much or too little refrigerant from the refilling, there may be secondary problems such as damage to the refrigerant cycle parts, or a decrease of cooling performance. Therefore, if it is determined that the refrigerant level is insufficient, completely remove refrigerant from the refrigerant cycle and refill with refrigerant to the specified amount.

Scheme 101

1. Use only ATMOS GU10 compressor oil for this vehicle. Using a PAG oil other than ATMOS GU10 compressor oil can damage the A/C compressor.
2. Do not spill ATMOS GU10 compressor oil on the vehicle. A drop of compressor oil on the vehicle surface can eat away at the paint. If oil gets on the vehicle, wipe it off immediately.
3. ATMOS GU10 compressor oil (PAG oil) has a higher moisture absorption efficiency than the previously used mineral oil. If moisture mixes with the compressor oil, the refrigerant system could be damaged. Therefore, install caps immediately after using the compressor oil or removing refrigerant system parts to prevent moisture absorption.

Scheme 102

1. Fully close the valves of the manifold gauge.
2. Connect the charging hoses to the high-and low-pressure side joints of the manifold gauge.
3. Connect the quick couplers to the ends of the charging hoses.
4. Connect the quick couplers to the charging valves.

Scheme 103

Scheme 104

1. Inspect the refrigerant pressure. «REFRIGERANT PRESSURE CHECK»(ref-177717-S37890013102005060400000) .
2. Place a dry-bulb thermometer in the driver-side center ventilator outlet.
3. Start the engine and after it is warmed up, run it at a constant 1,500 rpm .
4. Set the fan speed to MAX HI.
5. Turn the A/C switch on.
6. Set to RECIRCULATE mode.
7. Set the temperature control to MAX COLD.
8. Set to VENT mode.
9. Close all the doors and windows.
10. Wait until the air conditioner output temperature stabilizes. Stabilized condition The A/C compressor repeatedly turns on and off at regular intervals.
11. After the blower air is stabilized, read the dry-bulb thermometer.
12. Verify the ambient temperature.
13. Verify that the temperature reading is in the shaded zone. If the there is any malfunction, inspect the refrigerant system according to the troubleshooting chart.

REFRIGERANT CHARGING

Charging Recycled R-134a Refrigerant

1. Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer's instructions.

Scheme 105

1. Install the manifold gauge set.
2. Connect the tap pin side of the charging hose to the air purge valve of the manifold gauge.
3. Connect the vacuum pump hose to the center joint of the manifold gauge.
4. Connect the vacuum pump hose to the vacuum pump.
5. Connect the charging hose to the refrigerant tank.
6. Place the refrigerant tank on the scale. Regular amount of refrigerant (approx. quantity) 475-525 g {16.8-18.5 oz}

Scheme 106

Scheme 107

1. Open all the valves of the manifold gauge. CAUTION: Close the manifold gauge valve immediately after stopping the vacuum pump. If the valve is left open, the vacuum pump oil will flow back into the refrigeration cycle and cause a decrease in the efficiency of the air conditioner.
2. Start the vacuum pump and let it operate for 15 min.
3. Verify that high- and low-pressure side readings of the manifold gauge are at -101 kPa {-760 mmHg, -29.9 inHg}. Close each valve of the manifold gauge.

Airtightness Check

1. Stop the vacuum pump and wait for 5 min.
2. Check the high-and low-pressure side readings of the manifold gauge. If the reading has changed, inspect for leakage and go to «EVACUATION»(ref-177717-S30337667402005060400000) . If the reading has not changed, go to «CHARGING NEW R-134A REFRIGERANT»(ref-177717-S03066705822005060400000) .

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

1. Open the valve of the refrigerant tank.
2. Weigh the refrigerant tank to charge the suitable amount of refrigerant. WARNING: If the refrigerant system is charged with a large amount of refrigerant when inspecting for gas leakage, and if any leakage should occur, the refrigerant will be released into the atmosphere. In order to prevent the accidental release of refrigerant which can destroy the ozone layer in the stratosphere, follow the proper procedures and charge with only a small amount of refrigerant when inspecting for gas leakage. If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running. CAUTION: Always being charging of refrigerant from the high-pressure side. If changing is begun from the low-pressure side, the vanes of the A/C compressor will not be released and abnormal noise may result.
3. Open the high-pressure side valve of the manifold gauge.
4. When the low-pressure side reading increases to 0.098 MPa {1.0 kgf/cm 2 , 14 psi}, close the high-pressure side valve of the manifold gauge.
5. Inspect for leakage from the cooler pipe/hose connections using a gas leak tester. If there is no leakage, go to Step 7 . If leakage is found at a loose joint, tighten the joint, then go to the next step.
6. Inspect for leakage again. If there is no leakage after tightening the joint, go to the next step. If there is still a leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from evacuation. WARNING: If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.
7. Open the high-pressure side valve of the manifold gauge and charge with refrigerant until the weight of refrigerant tank has decreased 238-263 g {8.40-9.28 oz} from the amount in Step 2 .
8. Close the low-pressure side valve of the manifold gauge. WARNING: If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.
9. Start the engine and actuate the A/C compressor.
10. Open the low-pressure side valve of the manifold gauge and charge with refrigerant until the weight of the refrigerant tank has decreased regular amount from the amount in Step 2 .
11. Close the low-pressure side valve of the manifold gauge and the valve of the refrigerant tank.
12. Stop the engine and A/C compressor.

Scheme 113

1. Inspect for leakage using the a gas leak tester. If there is no leakage, go to Step 3 . If leakage is found at a loose joint, tighten the joint, then go to the next step.
2. Inspect for leakage again. If there is no leakage after tightening the joint, go to the next step. If there is still leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from evacuation.
3. Disconnect the manifold gauge from the charging valves.
4. Install the caps to the charging valves.

Scheme 114

1. Install the SST (49 C061 0A0B). «REFRIGERANT SYSTEM GENERAL PROCEDURES.»(ref-177717-S18592133752005060400000)
2. Start the engine and after it is warmed up, run it at a constant 1,500 rpm.
3. Set the fan speed MAX HI.
4. Turn the A/C switch on.
5. Set to RECIRCULATE mode.
6. Set the temperature control to MAX COLD.
7. Set to VENT mode.
8. Close all the doors and all the windows.
9. Measure the ambient temperature and high-and low-pressure side reading of the SST (49 C061 001A).
10. Verify that the intersection of the pressure reading of the SST (49 C061 001A) and ambient temperature is in the shaded zone. If there is any malfunction, inspect the refrigerant system according to the troubleshooting chart.

REFRIGERANT RECOVERY

1. Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer's instructions.

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

1. Disconnect the negative battery cable.
2. Discharge the refrigerant. «REFRIGERANT CHARGING»(ref-177717-S21873137252005060400000) .
3. Drain the engine coolant. See «COOLING SYSTEM»(ref-177562) .
4. Disconnect from the A/C unit in the order indicated in the figure. CAUTION: If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise or other malfunction could occur. Always plug open fittings immediately after removing any refrigeration cycle parts.
5. Remove the following parts: Front doors «FRONT DOOR REMOVAL/INSTALLATION»(ref-177731-S33616524532005060700000) . Ashtray panel See «CONSOLE REMOVAL/INSTALLATION»(ref-177786-S07028325542005060700000) . Console See «CONSOLE REMOVAL/INSTALLATION»(ref-177786-S07028325542005060700000) . Shift lever component (MTX). See «AUTOMATIC TRANSAXLE SHIFT MECHANISM»(ref-177780) . Selector lever component (ATX). See «SELECTOR LEVER COMPONENT REMOVAL/INSTALLATION»(ref-177780-S22412863032005060700000) . Decoration panel. See «DECORATION PANEL REMOVAL/INSTALLATION»(ref-177786-S19547422042005060700000) . Front scuff plate. See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-177786-S35097446782005060700000) . Front side trim. See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-177786-S00759394172005060700000) . Glove compartment. See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-177786-S24941703152005060700000) . Shower ducts (LH, RH) PJB. See «FUSES & CIRCUIT BREAKERS»(ref-168531) . Lower panel. See «LOWER PANEL REMOVAL/INSTALLATION»(ref-177786-S23426726492005060700000) . Column cover. See «COLUMN COVER REMOVAL/INSTALLATION»(ref-177786-S25465886942005060700000) . Steering shaft. See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION»(ref-177673-S09492789832005060300000) . A-pillar trim. See «A-PILLAR TRIM REMOVAL/INSTALLATION»(ref-177786-S26159187132005060700000) . Center panel module. See «INTERIOR TRIM»(ref-177786) . Windshield wiper arm and blade. See «WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALATION»(ref-177788-S15152889862005060700000) . Cowl grille. See «COWL GRILLE REMOVAL/INSTALLATION»(ref-177785-S07663231852005060700000) . Cowl panel. See «COWL PANEL REMOVAL/INSTALLATION»(ref-177729-S13496067802005060700000) . Windshield wiper motor. See «WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION»(ref-177788-S00751509092005060700000) .
6. Remove the A/C unit installation nut from the engine compartment, then remove the A/C unit. «A/C UNIT INSTALLATION NUT INSTALLATION NOTE»(ref-177717-S15148601242005060400000) . CAUTION: If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise or other malfunction could occur. Always plug open fittings immediately after removing any refrigeration cycle parts.
7. Remove the rear heat duct.
8. Disconnect the drain hose connected to the A/C unit.
9. Remove the nuts and bolts for installing the dashboard to the body.
10. Remove the dashboard with A/C unit. See «DASHBOARD REMOVAL/INSTALLATION»(ref-177786-S15974741452005060700000) .
11. Disconnect the air mix wire from the air mix link and wire clamp. (Manual air conditioner)
12. Disconnect the airflow mode wire from the airflow mode main link and wire clamp. (Manual air conditioner)
13. Disconnect the following connectors: Blower motor connector Evaporator temperature sensor connector Air intake actuator connector Resistor connector.
14. Remove the heater case.
15. Remove the nuts and bolts for installing the A/C unit to the dashboard.