Basic System (HVAC): Removal & Installation Mazda 3 BM

A/C Unit Installation Nut Removal Note

Note. If the adjusting bolt rotates when removing the A/C unit nut, keep rotating the nut. The adjusting bolt stops rotating when it contacts the A/C unit and the nut can be removed.

A/C Unit Nut. Scheme 31

Scheme 32

1. When replacing the A/C unit or evaporator, add compressor oil to the refrigerant cycle. Supplemental oil amount (approx. quantity) 30 ml {30 cc, 1.0 fl oz}
2. Tighten the A/C unit adjusting bolt until it lightly touches the A/C unit. (Scheme 32): Tightening A/C Unit Adjusting Bolt

Scheme 33

1. Install the clip as shown in the figure. (Scheme 33): Identifying Drain Hose Clip Installation

Scheme 34

1. While pressing the heater hose into the A/C unit side (1), pinch the quick connector retainer (2), then disconnect the heater hose from the A/C unit (3). (Scheme 34): Disconnecting Heater Hose From A/C Unit

Scheme 35

1. Insert the heater hose into the pipe of the A/C unit until a click is heard.
2. While pressing the heater hose quick connector against the A/C unit side, press in the push tab. (Scheme 35): Locating Push Tab
3. Verify that the heater hose cannot be pulled out from the A/C unit by lightly pulling the heater hose.

Airflow Mode Main Link Installation Note

Scheme 36

Scheme 37

Scheme 38

1. Set the airflow mode sub link to the A/C unit as shown in the figure. (Scheme 36): Identifying Airflow Mode Sub Link
2. Set the airflow mode main link to the A/C unit as shown in the figure. (Scheme 37): Identifying Airflow Mode Main Link
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 38): Identifying Airflow Mode Main Link

Scheme 39

Scheme 40

Scheme 41

1. Set the airflow mode sub link to the A/C unit as shown in the figure. (Scheme 39): Identifying Airflow Mode Sub Link
2. Set the airflow mode main link to the A/C unit as shown in the figure. (Scheme 40): Identifying Airflow Mode Main Link And Airflow Mode Rod
3. Install the airflow mode rod.
4. 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.
5. Rotate airflow mode main link and verify that each mode is accessed properly. (Scheme 41): Rotating Airflow Mode Main Link

Scheme 42

1. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]»(ref-579330-S31782573982013100700000).) (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).) (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-579332-S32330103212013100700000).)
2. Remove the following parts: Upper panel (See «UPPER PANEL REMOVAL/INSTALLATION»(ref-579335-S17519281862013100700000).) Shift lever knob (MTX) (See «MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [G35M-R]»(ref-579343-S30160104102013100700000).) (See «MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [G66M-R]»(ref-579344-S32573239452013100700000).) (See «MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [A26M-R]»(ref-579345-S39624684772013100700000).) (See «MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [C66M-R]»(ref-579346-S11482280202013100700000).) Selector lever knob (ATX) (See «AUTOMATIC TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION»(ref-579347-S14598286322013100700000).) Shift panel (See «SHIFT PANEL REMOVAL/INSTALLATION»(ref-579335-S24715706362013100700000).) Side wall (See «SIDE WALL REMOVAL/INSTALLATION»(ref-579335-S32642470872013100700000).) Console (See «CONSOLE REMOVAL/INSTALLATION»(ref-579335-S16951481782013100700000).) Front scuff plate (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-579335-S29057485522013100700000).) Front side trim (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-579335-S35549025382013100700000).) Fuel-filler lid opener lever cover (See «FUEL-FILLER LID OPENER AND LEVER REMOVAL/INSTALLATION»(ref-579383-S34040062722013100700000).)
3. Turn the floor covering over.
4. Remove in the order indicated in the table. (Scheme 42): Identifying Rear Heat Duct Component Removal Sequence
5. Install in the reverse order of removal.

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

1. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]»(ref-579330-S31782573982013100700000).) (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).) (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-579332-S32330103212013100700000).)
2. Discharge the refrigerant. (See «REFRIGERANT CHARGING»(ref-579408-S20461868102013100700000).)
3. Remove the aerodynamic under cover No.2. (See «AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-579341-S33007366072013100700000).)
4. Remove the drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579392-S33808663052013100700000).) (See «DRIVE BELT REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]»(ref-579359-S17755276772013100700000).) (See «DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-579373-S07897853642013100700000).)
5. Remove the water hose bracket. (Scheme 43): Identifying Water Hose Bracket 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.
6. Remove the clip. (MZR 2.0) (See «CLIP INSTALLATION NOTE»(ref-579378-S42277084432013100700000).) (Scheme 44): Identifying Harness And Cooler Hose Clip
7. Disconnect the connector.
8. Remove the bolt A. SKYACTIV-G 2.0 (Scheme 45): Identifying Cooler Hose, Connector And Bolts - SKYACTIV-G 2.0 With Torque Specifications (Scheme 46): Identifying Cooler Hose, Connector And Bolts - MZR 2.0 With Torque Specifications (Scheme 47): Identifying Cooler Hose, Connector And Bolts - MZR 2.5, MZR 2.3 DISI Turbo With Torque Specifications
9. Remove the cooler hose (LO). (See «REFRIGERANT LINE REMOVAL/INSTALLATION»(ref-579378-S08632172782013100700000).)
10. Remove the cooler hose (HI). (See «REFRIGERANT LINE REMOVAL/INSTALLATION»(ref-579378-S08632172782013100700000).)
11. Remove the nut and protector. (MZR 2.0) (with protector)
12. Remove the bolt B.
13. Remove the A/C compressor. Do not allow compressor oil to spill. (See «A/C COMPRESSOR INSTALLATION NOTE»(ref-579378-S09676719712013100700000).)
14. Install in the reverse order of removal.
15. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-579408-S02009140422013100700000).)

A/C Compressor Installation Note

Scheme 48

1. Rotate new A/C compressor shaft six to eight revolutions while collecting refrigerant oil in a clean measuring device. Use this refrigerant oil to refill new compressor. Do not allow refrigerant oil to become contaminated.
2. Rotate old A/C compressor shaft six to eight revolutions while collecting refrigerant oil in a separate, clean measuring device.
3. Compare those oil amounts. The amount of the oil drained from the new A/C compressor should be greater than the old one.
4. Pour the same amount oil of drained from the old A/C compressor back into the new A/C compressor. (Scheme 48): Pouring Same Amount Of Oil Drained From Old A/C Compressor Back Into A/C Compressor A/C compressor oil type FD46XG A/C compressor oil sealed volume (approx. quantity) SKYACTIV-G 2.0 100 ml {100 cc, 3.38 fl oz} MZR 2.0, MZR 2.5, MZR 2.3 DISI Turbo 120 ml {120 cc, 4.06 fl oz}

Scheme 49

1. Install the clip as shown in the figure. (Scheme 49): Identifying Harness And Cooler Hose Clip

Scheme 50

Scheme 51

1. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]»(ref-579330-S31782573982013100700000).) (See «BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579331-S30971870802013100700000).) (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-579332-S32330103212013100700000).)
2. Discharge the refrigerant. (See «REFRIGERANT CHARGING»(ref-579408-S20461868102013100700000).)
3. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.3 DISI TURBO]»(ref-579402-S28000546112013100700000).) (See «ENGINE COOLANT REPLACEMENT [MZR 2.0, MZR 2.5]»(ref-579357-S09737378012013100700000).) (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-579371-S39141873112013100700000).)
4. Remove the air cleaner. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579390-S14083409562013100700000).) (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]»(ref-579361-S37454927402013100700000).) (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-579374-S36284440572013100700000).)
5. Remove the aerodynamic under cover No.2. (See «AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-579341-S33007366072013100700000).)
6. Remove the aerodynamic under cover No.1. (See «AERODYNAMIC UNDER COVER NO.1 REMOVAL/INSTALLATION»(ref-579341-S03408133762013100700000).)
7. Remove the front bumper. (See «FRONT BUMPER REMOVAL/INSTALLATION»(ref-579342-S31619184642013100700000).)
8. Disconnect the radiator hose from the radiator.
9. Remove the cooling fan component. (See «COOLING FAN COMPONENT REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579402-S07545729522013100700000).) (See «COOLING FAN COMPONENT REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]»(ref-579357-S35338411722013100700000).) (See «COOLING FAN COMPONENT REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-579371-S08569932472013100700000).)
10. Remove the radiator. (See «RADIATOR REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO]»(ref-579402-S34747338622013100700000).) (See «RADIATOR REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]»(ref-579357-S41177059472013100700000).) (See «RADIATOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-579371-S01020012222013100700000).)
11. Disconnect the cooler hose (HI) and cooler pipe. Do not allow remaining compressor oil in the refrigerant line to spill. (See «REFRIGERANT LINE REMOVAL/INSTALLATION»(ref-579378-S08632172782013100700000).) 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.
12. Remove the condenser, being careful not to allow remaining compressor oil in the condenser to spill. (See «CONDENSER INSTALLATION NOTE»(ref-579378-S10592340652013100700000).) MZR 2.0, MZR 2.5, SKYACTIV-G 2.0 (4SD), SKYACTIV-G 2.0 (5HB, vehicles with receiver/drier on vehicle right) (Scheme 50): Identifying Condenser Removal - MZR 2.0, MZR 2.5, SKYACTIV-G 2.0 (4SD), SKYACTIV-G 2.0 (5HB, Vehicles With Receiver/Drier On Vehicle Right) With Torque Specifications MZR 2.3 DISI Turbo, SKYACTIV-G 2.0 (5HB, vehicles with receiver/drier on vehicle left) (Scheme 51): Identifying Condenser - MZR 2.3 DISI Turbo, SKYACTIV-G 2.0 (5HB, Vehicles With Receiver/Drier On Vehicle Left) With Torque Specifications 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.
13. Install in the reverse order of removal.
14. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 2.3 DISI TURBO]»(ref-579402-S03595379622013100700000).) (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 2.0, MZR 2.5]»(ref-579357-S23872117182013100700000).) (See «ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 2.0]»(ref-579371-S17337441142013100700000).)
15. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-579408-S02009140422013100700000).)

Condenser Installation Note

1. After replacing the condenser, add compressor oil to the refrigeration cycle. Supplemental oil amount (approx. quantity) 20 ml {20 cc, 0.68 fl oz}

Refrigerant Line Installation Note

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

Scheme 52

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 52): Tightening Connection Bolt Or Nut With Torque Wrench

Scheme 53

1. Connect the male pipe or hose by 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 53): Connecting Male Pipe Or Hose Until Garter Spring Is Over Flared End Of Female Pipe

Cooler Hose (LO) Installation Note

1. After replacing the cooler hose (LO), add compressor oil to the refrigeration cycle. Supplemental oil amount (approx. quantity) 10 ml {10 cc, 0.34 fl oz}

Cooler Pipe Installation Note

1. After replacing the cooler pipe, add compressor oil to the refrigeration cycle. Supplemental oil amount (approx. quantity) 5 ml {5 cc, 0.2 fl oz}