HVAC System: Removal & Installation Mazda 3 BK

A/C Unit Installation Note

1. When replacing the A/C unit or evaporator, add compressor oil to the refrigerant cycle. Supplemental oil amount (approx. quantity) 20 ml {20 cc, 0.7 fl oz}

Scheme 25

1. Tighten it to the right so that it is flush to the contact surface.

Scheme 26

1. Disassemble in the order indicated in the figure. CAUTION: If a non-specified grease is used, it may result in abnormal noise or improper operation of the links. Apply only the specified grease to each link.
2. Assemble in the reverse order of disassembly.

Scheme 27

1. Attach the sensor clamp as shown in the figure.

Scheme 28

1. Assemble the evaporator temperature sensor as shown in the figure.

Scheme 29

1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. See «REFRIGERANT RECOVERY»(ref-177717-S29446860652005060400000) . See «REFRIGERANT CHARGING»(ref-177717-S21873137252005060400000) . CAUTION: If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.
3. Disconnect the cooler hose (LO) and cooler pipe. Do not allow compressor oil to spill. «REFRIGERANT LINES REMOVAL/INSTALLATION»(ref-177717-S30617907582005060400000) .
4. Remove the PJB. See «FUSES & CIRCUIT BREAKERS»(ref-168531) .
5. Remove the shower duct (RH).
6. Remove the bolt and shift the evaporator pipe. Do not allow compressor oil to spill.
7. Remove the expansion valve. Do not allow compressor oil to spill.
8. Install in the reverse order of removal.
9. Perform the refrigerant system performance test. «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-177717-S02744042172005060400000) .

Airflow Mode Main Link Installation Note

Scheme 30

Scheme 31

1. Push and hold each airflow mode sub link in the direction of the arrow.
2. Set the airflow mode main link to the A/C unit as shown in the figure.
3. Press the airflow mode main link lightly to the A/C unit it in the direction shown by the arrow, then set the projections of each airflow mode sub link into the grooves of the airflow mode main link.
4. Rotate airflow mode main link and verify that each mode is accessed properly.

Scheme 32

Scheme 33

1. Disconnect the negative battery cable.
2. Remove the following parts: Front seat. See «FRONT SEAT REMOVAL/INSTALLATION»(ref-177805-S06736237262005060700000) . Rear seat. See «REAR SEAT REMOVAL/INSTALLATION»(ref-177805-S40569716222005060700000) . Front scuff plate. See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-177786-S35097446782005060700000) . Console. See «CONSOLE REMOVAL/INSTALLATION»(ref-177786-S07028325542005060700000) . Front side trim. See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-177786-S00759394172005060700000) . Rear scuff plate. See «REAR SCUFF PLATE REMOVAL/INSTALLATION»(ref-177786-S15571640632005060700000) . B-pillar lower trim. See «B-PILLAR LOWER TRIM REMOVAL/INSTALLATION»(ref-177786-S07584945072005060700000) . Lower anchor of the front seat belt. See «FRONT SEAT BELT REMOVAL/INSTALLATION»(ref-177794-S05376933222005060700000) . Tire house trim. See «TIRE HOUSE TRIM REMOVAL/INSTALLATION»(ref-177786-S13536083402005060700000) . Fuel-filler lid opener lever cover. See «FUEL-FILLER LID OPENER REMOVAL/INSTALLATION»(ref-177783-S07972637142005060700000) . Floor covering. See «INTERIOR TRIM»(ref-177786) .
3. Remove in the order indicated in the figure.
4. Install in the reverse order of removal.

Scheme 34

Scheme 35

1. Disconnect the negative battery cable.
2. Discharge the refrigerant. «REFRIGERANT CHARGING»(ref-177717-S21873137252005060400000) .
3. Remove the splash shield.
4. Remove the A/C drive belt. See «DRIVE BELT REPLACEMENT»(ref-177560-S02976814522005060200000) .
5. Detach the two wiring harness clamps.
6. Disconnect the cooler hose (LO) and cooler hose (HI). Do not allow remaining compressor oil in the refrigerant line to spill. See «REFRIGERANT LINE REMOVAL NOTE»(ref-177717-S15259600112005060400000) . See «REFRIGERANT LINE INSTALLATION NOTE»(ref-177717-S19464337852005060400000) . 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 compressor protector.
8. Remove in the order indicated in the figure. Do not allow remaining compressor oil in the A/C compressor to spill. 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.
9. Install in the reverse order of removal.
10. Perform the refrigerant system performance test. «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-177717-S02744042172005060400000) .

A/C Compressor Installation Note

1. When replacing the A/C compressor, remove the following amount of compressor oil from the new A/C compressor. Amount drained (approx. quantity) 155 ml {155 cc, 5.24 fl oz} - [compressor oil from old A/C compressor + 15 ml {15 cc, 0.5 fl oz}]

Scheme 36

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. Remove the fresh air duct cover. See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-177563-S27802206012005060200000) . See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3]»(ref-177563-S01004479692005060200000) .
5. Remove the air cleaner. See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-177563-S27802206012005060200000) . See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3]»(ref-177563-S01004479692005060200000) .
6. Remove the plash shield.
7. Drain the ATF. (ATX) See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT»(ref-177779-S28709390042005060700000) .
8. Disconnect the cooler pipe and cooler hose (Hl). Do not allow remaining compressor oil in the refrigerant line to spill. CAUTION: If moisture or foreign material enters the refrigerant 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.
9. Disconnect the radiator hose from the radiator.
10. Disconnect the oil hose from the oil cooler. (ATX)
11. Remove the cooling fan. See «RADIATOR REMOVAL/INSTALLATION»(ref-177562-S08623934542005060200000) .
12. Remove the oil cooler. (ATX) See «OIL COOLER REMOVAL/INSTALLATION [AUTOMATIC TRANSAXLE]»(ref-177779-S40029279742005060700000) .
13. Remove the radiator with the condenser installed. See «RADIATOR REMOVAL/INSTALLATION»(ref-177562-S08623934542005060200000) .
14. Release the radiator hook and pull the condenser up, being careful not to allow remaining compressor oil in the condenser to spill. See «CONDENSER INSTALLATION NOTE»(ref-177717-S39334375042005060400000) . 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.
15. Install in the reverse order of removal.
16. Perform the refrigerant system performance test. See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-177717-S02744042172005060400000) .

Condenser Installation Note

1. After replacing the condenser, add compressor oil to the refrigeration cycle. Supplemental oil amount (approx. quantity) 20 ml {20 cc, 0.7 fl oz}

Refrigerant Line Installation Note

1. Apply compressor oil to the O-rings and connect the joints.
2. Tighten the joints.

Scheme 37

1. Tighten the bolt of joint by hand.
2. Connect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly, then tighten the connection bolt or nut with a torque wrench.

Scheme 38

1. Connect the male pipe or hose by pushing it while slightly twisting it onto female pipe until the garter spring at the male pipe or hose is over the flared end of female pipe. NOTE: When the male pipe or hose is replaced, the indicator ring comes out after connecting to indicate that it is locked.

Scheme 39

Scheme 40

Scheme 41

1. Disconnect the negative battery cable.
2. Remove the front scuff plate. See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-177786-S35097446782005060700000) .
3. Remove the front side trim. See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-177786-S00759394172005060700000) .
4. Remove the decoration panel. See «DECORATION PANEL REMOVAL/INSTALLATION»(ref-177786-S19547422042005060700000) .
5. Remove the glove compartment. See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-177786-S24941703152005060700000) .
6. Remove the car-navigation unit. See «CAR-NAVIGATION SYSTEM»(ref-216090-S22984884282006011700000) .
7. Remove in the order indicated in the figure.
8. Install in the reverse order of removal.

Scheme 42

Scheme 43

1. Connect battery positive voltage to air intake actuator terminal C (or G), connect terminal G (or E) to ground, and then verify that the air intake actuator operates as shown in the figure. If the operation condition is not normal, replace the air intake actuator.

BLOWER MOTOR REMOVAL

Note. The blower motor is located on the A/C unit as shown in the figure. Perform the work from the front passenger's side in the posture shown in the figure.

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

1. Set the air intake mode to FRESH.
2. Disconnect the negative battery cable.
3. Remove the following parts: Front side trim (RH). See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-177786-S00759394172005060700000) . Front scuff plate (RH). See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-177786-S35097446782005060700000) . Decoration panel. See «DECORATION PANEL REMOVAL/INSTALLATION»(ref-177786-S19547422042005060700000) . Glove compartment. See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-177786-S24941703152005060700000) . PJB and PJB bracket. See «FUSES & CIRCUIT BREAKERS»(ref-168531) . Car-navigation unit. See «CAR-NAVIGATION SYSTEM»(ref-216090-S22984884282006011700000) . Auto leveling control module. See «AUTO LEVELING SENSOR REMOVAL/INSTALLATION»(ref-169785-S03356401862004121600000) .
4. Disconnect the air intake actuator connector.
5. Remove the screws shown in the figure, then remove the blower case.
6. Remove the air guide.
7. Install the SST (49 B061 015) to the blower motor. See «SST Installation Note»(ref-177717-S16820154372005060400000) .
8. Detach the hood release lever from the lower panel. See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-177783-S33436475022005060700000) .
9. Remove the front scuff plate. See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-177786-S35097446782005060700000) .
10. Remove the front side trim. See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-177786-S00759394172005060700000) .
11. Remove the lower panel. See «LOWER PANEL REMOVAL/INSTALLATION»(ref-177786-S23426726492005060700000) .
12. Disconnect the resistor connector.
13. Disconnect the blower motor cooling pipe connected to the blower motor.
14. Disconnect the blower motor connector as shown in the figure.
15. Remove the blower motor cover. See «BLOWER MOTOR COVER REMOVAL NOTE»(ref-177717-S32420878112005060400000) . CAUTION: When the blower motor cover is removed, the blower motor could fall in the A/C unit case causing the sirocco fan to be damaged. Therefore another person must hold the blower motor at the installation position.
16. Remove the blower motor by pulling it out. See «BLOWER MOTOR REMOVAL NOTE»(ref-177717-S18899752992005060400000) .

Scheme 50

Scheme 51

Scheme 52

1. Align the SST (49 B061 015) guide with the sirocco fan clip and insert the SST (49 B061 015) tabs ( 3 ) into the three set holes on the blower motor.
2. Rotate the SST (49 B061 015) clockwise to lock the SST and blower motor.

Scheme 53

1. Pull the lock on the top of the blower motor cover and rotate the blower motor cover clockwise.

Scheme 54

1. Caution To prevent damage to the sirocco fan, pull the blower motor out being careful that the blower motor does not interfere with the A/C unit.

Scheme 55

Scheme 56

1. Install the SST to the blower motor. See «SST Installation Note»(ref-177717-S16820154372005060400000) .
2. Install the blower motor with the SST (49 B061 015) installed, to the A/C unit. See «BLOWER MOTOR INSTALLATION NOTE»(ref-177717-S27159106262005060400000) .
3. Install the blower motor cover from the driver's side. See «BLOWER MOTOR COVER INSTALLATION NOTE»(ref-177717-S09865078462005060400000) .
4. Remove the SST (49 B061 015) from the blower motor.
5. Connect the blower motor connector as shown in the figure.
6. Install the blower motor cooling pipe.
7. Install the air guide.
8. Connect the resistor connector.
9. Install the lower panel. See «LOWER PANEL REMOVAL/INSTALLATION»(ref-177786-S23426726492005060700000) .
10. Install the front side trim. See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-177786-S00759394172005060700000) .
11. Install the front scuff plate. See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-177786-S35097446782005060700000) .
12. Install the hood release lever from the lower panel. See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-177783-S33436475022005060700000) .
13. Install the blower case with the intake door at FRESH. See «BLOWER CASE INSTALLATION NOTE»(ref-177717-S05016644262005060400000) .
14. Connect the air intake actuator connector.
15. Install the following parts: Auto leveling control module. See «AUTO LEVELING SENSOR REMOVAL/INSTALLATION»(ref-169785-S03356401862004121600000) . Car-navigation unit. See «CAR-NAVIGATION SYSTEM»(ref-216090-S22984884282006011700000) . PJB and PJB bracket. See «FUSES & CIRCUIT BREAKERS»(ref-168531) . Glove compartment. See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-177786-S24941703152005060700000) . Decoration panel. See «DECORATION PANEL REMOVAL/INSTALLATION»(ref-177786-S19547422042005060700000) . Front scuff plate (RH). See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-177786-S35097446782005060700000) . Front side trim (RH). See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-177786-S00759394172005060700000) .

Scheme 57

1. Position the blower motor projection upward and install the blower motor to the A/C unit. CAUTION: To prevent damage to the sirocco fan, install the blower motor being careful that the blower motor does not interfere with the A/C unit. Also, another person must hold the blower motor at the installation position.

Scheme 58

1. To install, rotate the blower motor cover until a click is heard.

Scheme 59

Scheme 60

1. If not replacing the blower case, replace the adhesive polyurethane on the fresh-air inlet of the blower case. CAUTION: To adhere new polyurethane properly, be sure to remove the adhesive agent and adhesive polyurethane completely. NOTE: If the blower case is removed, the adhesive polyurethane can be damaged. Damaged adhesive polyurethane could cause abnormal noise or other malfunctions, therefore replace it.
2. Insert the screw into the blower case and install the case to the A/C unit.

Stator and Thermal Protector Removal Note

1. After removing the stator and thermal protector, completely remove the silicone adhering to the A/C compressor side.

Scheme 61

1. Apply approx. 1 g {0.04 oz} of silicone (Shin-Etsu Silicone KE-347W or similar) to the contact surface of the thermal protector, then thoroughly install it onto the A/C compressor, leaving no gaps.

Clamp Installation Note

1. When installing a new stator and thermal protector, replace the clamp.

Screw Installation Note

1. When installing a new stator and thermal protector, replace the screw.

Scheme 62

1. When installing a new pressure plate, A/C compressor pulley, stator, or A/C compressor body, replace the snap ring.

Scheme 63

Scheme 64

1. Measure the clearance around the entire circumference between the pressure plate and A/C compressor pulley using a thickness gauge.
2. Verify that the clearance. If not within the specification, remove the pressure plate and adjust the clearance by changing the shim ( 0.2 mm {0.008 in}, 0.5 mm {0.02 in} ) or the number of shims. Clearance 0.3-0.5 mm {0.012-0.019 in}

Scheme 65

Scheme 66

1. Connect battery positive voltage to magnetic clutch terminal A and the A/C compressor body to ground.
2. Verify that the magnetic clutch operates. If there is any malfunction, replace the stator and thermal protector.

EVAPORATOR TEMPERATURE SENSOR REMOVAL/INSTALLATION

1. Remove the evaporator temperature sensor from the A/C unit. See «A/C UNIT DISASSEMBLY/ASSEMBLY»(ref-177717-S30999156572005060400000) .

Refrigerant Pressure Switch Installation Note

1. Apply compressor oil to O-ring and connect the joint.

Scheme 67

Scheme 68

Scheme 69

1. Install the SST (gas charging set).
2. Disconnect the refrigerant pressure switch connector.
3. Verify the high-pressure side reading of the SST (manifold gauge) and continuity between the refrigerant pressure switch terminals. If there is any malfunction, replace the refrigerant pressure switch.

Scheme 70

1. Disconnect the negative battery cable.
2. Remove the following parts: Ashtray panel. See «CONSOLE REMOVAL/INSTALLATION»(ref-177786-S07028325542005060700000) . Detach the hood release lever from the lower panel. See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-177783-S33436475022005060700000) . Front scuff plate. See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-177786-S35097446782005060700000) . Front side trim. See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-177786-S00759394172005060700000) . Lower panel. See «LOWER PANEL REMOVAL/INSTALLATION»(ref-177786-S23426726492005060700000) . Decoration panel. See «DECORATION PANEL REMOVAL/INSTALLATION»(ref-177786-S19547422042005060700000) . Glove compartment. See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-177786-S24941703152005060700000) . PJB and PJB bracket. See «FUSES & CIRCUIT BREAKERS»(ref-168531) .
3. Detach the PJB wiring harness clamp from the dashboard.
4. Remove the center panel module. See «INTERIOR TRIM»(ref-177786) .
5. Remove the air mix wire and airflow mode wire from the A/C unit.
6. Release the left and right tabs and remove in the order indicated in the figure.

Scheme 71

Scheme 72

1. Pass each wire through the following routes and connect to A/C unit.
2. Connect the climate control unit connectors.
3. Adjust the climate control unit wires. «CLIMATE CONTROL UNIT WIRE ADJUSTMENT»(ref-177717-S26120315952005060400000) .
4. Install the following parts: PJB and PJB bracket. See «FUSES & CIRCUIT BREAKERS»(ref-168531) . Glove compartment. See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-177786-S24941703152005060700000) . Decoration panel. See «DECORATION PANEL REMOVAL/INSTALLATION»(ref-177786-S19547422042005060700000) . Lower panel. See «LOWER PANEL REMOVAL/INSTALLATION»(ref-177786-S23426726492005060700000) . Front side trim. See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-177786-S00759394172005060700000) . Front scuff plate. See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-177786-S35097446782005060700000) . Detach the hood release lever from the lower panel. See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-177783-S33436475022005060700000) . Ashtray panel. See «CONSOLE REMOVAL/INSTALLATION»(ref-177786-S07028325542005060700000) . Climate control unit Center panel module. See «INTERIOR TRIM»(ref-177786) .
5. Connect the negative battery cable.

Scheme 73

1. Disassemble in the order indicated in the figure.
2. Assemble in the reverse order of disassembly.

Scheme 74

1. Disassemble the wires as shown in the figure.

Scheme 75

Scheme 76

1. Assemble the wires at the positions shown in the figure.
2. Assemble E-ring with the wire pressed against surface A. If the E-ring has been lost, the one at the wire end can be removed and reused.

Scheme 77

1. Set the temperature control dial at middle position (MAX HOT-MAX COLD). CAUTION: If the air mix wire is set without first fixing the air mix link position, it is possible that the air mix door cannot be switched normally.
2. Set the air mix sub link to the middle position (MAX HOT-MAX COLD) and insert an approx. No. 5 Phillips screwdriver into the set hole to fix the position of the link.
3. Connect the air mix wire to air mix link.
4. Clamp the air mix wire to wire clamp.
5. Remove the screwdriver and verify that the temperature control dial can move its full stroke.

Scheme 78

1. Set the airflow mode selector dial at defroster. CAUTION: If the airflow mode wire is set without first fixing the airflow mode main link position, it is possible that the airflow mode door cannot be switched normally.
2. Set the airflow mode main link to the vent position and insert an approx. No. 5 Phillips screwdriver into the set hole to fix the position of the link.
3. Connect the airflow mode wire to airflow mode main link.
4. Clamp the airflow mode wire to wire clamp.
5. Remove the screwdriver and verify that the airflow mode selector dial can move its full stroke.