Control System (HVAC): Removal & Installation Mazda 3 BL

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.

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Scheme 78

1. Set the air intake mode to FRESH.
2. Disconnect the negative battery cable.
3. Remove the following parts: Front scuff plate (RH) (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-345251-S03552764762009102000000) .) Front side trim (RH) (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-345251-S39582742522009102000000) .) Decoration panel (See «DECORATION PANEL REMOVAL/INSTALLATION»(ref-345251-S26486634232009102000000) .) Glove compartment (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-345251-S25078258972009102000000) .) Hood release lever (See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-345243-S34551921912009102000000) .) Lower Panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-345251-S05584420032009102000000) .) Column cover (See «COLUMN COVER REMOVAL/INSTALLATION»(ref-345251-S35932273802009102000000) .) Meter hood (See «METER HOOD REMOVAL/INSTALLATION»(ref-345251-S07110092202009102000000) .) Instrument cluster (See «INSTRUMENT CLUSTER REMOVAL/INSTALLATION»(ref-345262-S32996487732009102000000) .) Steering shaft (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION»(ref-345219-S02633973402009102000000) .) Accelerator pedal (See «ACCELERATOR PEDAL REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345225-S27974467802009102000000) or «ACCELERATOR PEDAL REMOVAL/INSTALLATION [LF, L3]»(ref-345212-S01618660652009102000000) .) Brake pedal (See «BRAKE PEDAL REMOVAL/INSTALLATION»(ref-345233-S17425213882009102000000) .) PJB and PJB bracket (See «PASSENGER JUNCTION BOX (PJB) REMOVAL/INSTALLATION»(ref-345241-S29864541242009102000000) .) Car-navigation unit (See «CAR-NAVIGATION UNIT REMOVAL/INSTALLATION»(ref-345255-S26831542572009102000000) .) Auto leveling control module
4. Cut off the temporary steering stay on the passenger's side.
5. Remove the screws shown in the figure and slide the blower case. LF, L3 L3 with TC
6. Disconnect the air intake actuator connector.
7. Remove the blower case shown in the figure. LF, L3 L3 with TC
8. Remove the air guide.
9. Install the SST (49 B061 015) to the blower motor. (See «SST INSTALLATION NOTE»(ref-345245-S41375618712009102000000) ).
10. Disconnect the resistor connector. (Manual air conditioner)
11. Disconnect the blower motor cooling pipe connected to the blower motor.
12. Remove the airflow mode actuator. (See «AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION»(ref-345245-S14475301992009102000000) ).
13. Disconnect the blower motor connector as shown in the figure.
14. Remove the blower motor cover. (See «BLOWER MOTOR COVER REMOVAL NOTE»(ref-345245-S38795590992009102000000) ). 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.
15. Remove the blower motor by pulling it out. (See «BLOWER MOTOR REMOVAL NOTE»(ref-345245-S42539952192009102000000) ).

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Scheme 81

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

Scheme 82

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

Scheme 83

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Scheme 85

1. Install the SST to the blower motor. (See «BLOWER MOTOR REMOVAL»(ref-345245-S07597598002009102000000) ).
2. Install the blower motor with the SST (49 B061 015) installed, to the A/C unit. (See «BLOWER MOTOR INSTALLATION NOTE»(ref-345245-S38678716452009102000000) ).
3. Install the blower motor cover from the driver's side. (See «BLOWER MOTOR COVER INSTALLATION NOTE»(ref-345245-S11037333272009102000000) ).
4. Connect the blower motor connector as shown in the figure.
5. Install the blower motor cooling pipe.
6. Remove the SST (49 B061 015) from the blower motor.
7. Install the airflow mode actuator. (See «AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION»(ref-345245-S14475301992009102000000) ).
8. Install the air guide.
9. Connect the resistor connector. (Manual air conditioner)
10. Install the blower case. CAUTION: Install the blower case while pressing the dashboard insulator, otherwise the blower case could be damaged.
11. Connect the air intake actuator connector.
12. Install the following parts: Auto leveling control module Car-navigation unit (See «CAR-NAVIGATION UNIT REMOVAL/INSTALLATION»(ref-345255-S26831542572009102000000) .) PJB and PJB bracket (See «PASSENGER JUNCTION BOX (PJB) REMOVAL/INSTALLATION»(ref-345241-S29864541242009102000000) .) Brake pedal (See «BRAKE PEDAL REMOVAL/INSTALLATION»(ref-345233-S17425213882009102000000) .) Accelerator pedal (See «ACCELERATOR PEDAL REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345225-S27974467802009102000000) or «ACCELERATOR PEDAL REMOVAL/INSTALLATION [LF, L3]»(ref-345212-S01618660652009102000000) .) Steering shaft (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION»(ref-345219-S02633973402009102000000) .) Instrument cluster (See «INSTRUMENT CLUSTER REMOVAL/INSTALLATION»(ref-345262-S32996487732009102000000) .) Meter hood (See «METER HOOD REMOVAL/INSTALLATION»(ref-345251-S07110092202009102000000) .) Column cover (See «COLUMN COVER REMOVAL/INSTALLATION»(ref-345251-S35932273802009102000000) .) Lower panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-345251-S05584420032009102000000) .) Hood release lever (See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-345243-S34551921912009102000000) .) Glove compartment (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-345251-S25078258972009102000000) .) Decoration panel (See «DECORATION PANEL REMOVAL/INSTALLATION»(ref-345251-S26486634232009102000000) .) Front side trim (RH) (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-345251-S39582742522009102000000) .) Front scuff plate (RH) (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-345251-S03552764762009102000000) .)

Scheme 86

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 87

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

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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 or installed, 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.
3. Install the blower case by inserting and rotating it in the directions of the arrows shown in the figure. LF, L3 L3 with TC

Bolt Removal/Installation Note

Note. If there are only 2 prepackaged bolts available when replacing the compression with a repair part, select bolts from the replaced unit of the same length as the prepackaged bolts.

Scheme 92

1. When removing or installing the bolt, hold the pressure plate in place as shown in the figure.
2. When installing a new A/C compressor body, replace the bolt.

Scheme 93

1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
3. Adjust the magnetic clutch clearance. (See «MAGNETIC CLUTCH ADJUSTMENT»(ref-345245-S40272007792009102000000) ).

1. When removing or installing the bolt, hold the pressure plate in place as shown in the figure.
2. When installing a new A/C compressor body, replace the recommended bolt.

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 94

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/Q compressor, leaving no gaps.

Screw Installation Note

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

Clamp Installation Note

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

Scheme 95

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

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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}

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

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Scheme 101

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.

Scheme 102

1. Disconnect the negative battery cable.
2. Pry the solar radiation sensor from the dashboard using a flathead screwdriver wrapped with protective tape.
3. Remove in the order indicated in the table. CAUTION: After the solar radiation sensor removal, the sensor connector could fall in the dashboard making the installation difficult. Therefore, hold the rooted end of the sensor connector using a clip or similar tool to prevent it from falling.
4. Install in the reverse order of removal.

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1. Shine a fluorescent light or expose the solar radiation sensor to natural sunlight.
2. Connect the positive (+) lead to terminal A and the negative (-) lead to terminal B of the solar radiation sensor, and verify that the voltages are as shown in the table. If the voltage is not as specified, replace the solar radiation sensor.

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1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table. LF, L3 L3 with TC
3. Install in the reverse order of removal.

Scheme 107

1. Measure the temperature around the ambient temperature sensor and measure the resistance between the ambient temperature sensor terminal. If the characteristics of the ambient temperature sensor are not as shown in the graph, replace the ambient temperature sensor.

Scheme 108

1. Disconnect the negative battery cable.
2. Remove the lower panel. (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-345251-S05584420032009102000000) .)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

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1. Measure the temperature around the passenger compartment temperature sensor and measure the resistance between passenger compartment temperature sensor terminals B and D. If the characteristics of the passenger compartment temperature sensor are not as shown in the graph, replace the passenger compartment temperature sensor.
2. Connect battery positive voltage to passenger compartment temperature sensor terminal A and connect terminal C to ground to verify fan operation. If there is any malfunction, replace the passenger compartment temperature sensor.

EVAPORATOR TEMPERATURE SENSOR REMOVAL/INSTALLATION

1. Remove the evaporator temperature sensor from the A/C unit. (See «A/C UNIT DISASSEMBLY/ASSEMBLY [FULL-AUTO AIR CONDITIONER]»(ref-345211-S03170547872009102000000) .) (See «A/C UNIT DISASSEMBLY/ASSEMBLY [MANUAL AIR CONDITIONER]»(ref-345211-S30039170702009102000000) .)

Refrigerant Pressure Switch Installation Note

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

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

Scheme 114

1. Disconnect the negative battery cable.
2. Remove the ashtray panel.
3. Remove the console. (See «CONSOLE REMOVAL/INSTALLATION»(ref-345251-S09223885732009102000000) .)
4. Remove the decoration panel. (See «DECORATION PANEL REMOVAL/INSTALLATION»(ref-345251-S26486634232009102000000) .)
5. Remove the center panel module. (See «CENTER PANEL UNIT REMOVAL/INSTALLATION»(ref-345255-S26714161172009102000000) .)
6. Release the left and right tabs and remove as shown in the figure.
7. Install in the reverse order of removal.

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1. Disconnect the negative battery cable.
2. Remove the following parts: Ashtray panel Detach the hood release lever from the lower panel. (See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-345243-S34551921912009102000000) .) Front scuff plate (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-345251-S03552764762009102000000) .) Front side trim (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-345251-S39582742522009102000000) .) Lower panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-345251-S05584420032009102000000) .) Decoration panel (See «DECORATION PANEL REMOVAL/INSTALLATION»(ref-345251-S26486634232009102000000) .) Glove compartment (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-345251-S25078258972009102000000) .) PJB and PJB bracket (See «PASSENGER JUNCTION BOX (PJB) REMOVAL/INSTALLATION»(ref-345241-S29864541242009102000000) .) Console (See «CONSOLE REMOVAL/INSTALLATION»(ref-345251-S09223885732009102000000) .)
3. Detach the PJB wiring harness clamp from the dashboard.
4. Remove the center panel module. (See «CENTER PANEL UNIT REMOVAL/INSTALLATION»(ref-345255-S26714161172009102000000) .)
5. Remove the wire clamp screws from the A/C unit at the positions shown in the figure.
6. Remove the air mix wire and airflow mode wire. Pull the wire in the direction shown by the arrow and remove it while pressing the link tab.
7. Release the left and right tabs and remove in the order indicated in the table.
8. Remove the E-rings from the air mix wire and airflow mode wire, slide the wires in the direction shown by the arrow, then remove the wire clamps from the air mix wire and airflow mode wire.

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1. Install the wire clamp to the A/C unit.
2. Set the temperature control dial at MAX COLD.
3. Set the airflow mode selector dial at defroster.
4. Install the E-rings to each position on the wires shown in the figure.
5. Pass each wire through the following routes and connect to A/C unit.
6. Connect the climate control unit connectors.
7. Install the climate control unit.
8. Adjust the climate control unit wires. (See «CLIMATE CONTROL UNIT WIRE ADJUSTMENT»(ref-345245-S26034471002009102000000) ).
9. Install the center panel module.
10. Attach the PJB wiring harness clamp to dashboard.
11. Install the following parts: Console (See «CONSOLE REMOVAL/INSTALLATION»(ref-345251-S09223885732009102000000) .) PJB and PJB bracket. (See «PASSENGER JUNCTION BOX (PJB) REMOVAL/INSTALLATION»(ref-345241-S29864541242009102000000) .) Glove compartment (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-345251-S25078258972009102000000) .) Decoration panel (See «DECORATION PANEL REMOVAL/INSTALLATION»(ref-345251-S26486634232009102000000) .) Lower panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-345251-S05584420032009102000000) .) Front side trim (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-345251-S39582742522009102000000) .) Front scuff plate (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-345251-S03552764762009102000000) .) Detach the hood release lever from the lower panel. (See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-345243-S34551921912009102000000) .) Ashtray panel
12. Connect the negative battery cable.

Scheme 121

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

Scheme 122

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

Scheme 123

1. Disassemble the wires as shown in the figure.

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Scheme 125

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 beer lost, the one at the wire end can be removed and reused.