Basic System (HVAC): Removal & Installation Mazda 5 I

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.

Scheme 12

Scheme 13

1. When replacing the A/C unit or evaporator, add compressor oil to the refrigerant cycle. Supplemental oil amount (approx. quantity) 25 ml {25 cc, 0.8 fl oz}
2. Tighten the A/C unit adjusting bolt until it lightly touches the A/C unit.

Scheme 14

1. Disassemble in the order indicated in the table. 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 15

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

Scheme 16

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

Scheme 17

1. Assemble the adhesive polyurethane (5) as shown in the figure.

Scheme 18

1. Assemble the adhesive polyurethane (4) as shown in the figure.

Scheme 19

1. Assemble the adhesive polyurethane (3) as shown in the figure.

Scheme 20

1. Disassemble in the order indicated in the table. 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 21

1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
2. Disconnect the negative battery cable.
3. Discharge the refrigerant from the system. (See «REFRIGERANT RECOVERY»(ref-244391-S18745100282006092100000) ). (See «REFRIGERANT CHARGING»(ref-244391-S42129033012006092100000) ). 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.
4. Disconnect the cooler hose (LO) and cooler pipe. Do not allow compressor oil to spill. (See «REFRIGERANT LINES REMOVAL/INSTALLATION»(ref-244331-S03928268132006092100000) ).
5. Remove the following parts: Front scuff plate inner (RH) (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-244361-S26008392432006092100000) ). Front side trim (RH) (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-244361-S28323081802006092100000) ). Side panel (RH) (See «SIDE PANEL REMOVAL/INSTALLATION»(ref-244361-S16170239572006092100000) ). Side wall (See «SIDE WALL REMOVAL/INSTALLATION»(ref-244361-S31703119622006092100000) ). Shift lever component (MTX) (See «MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION»(ref-244380-S36947017532006092100000) ). Selector lever component (ATX) (See «SELECTOR LEVER COMPONENT REMOVAL/INSTALLATION»(ref-244377-S02725560272006092100000) ). Front console (See «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-244361-S03102331672006092100000) ). Glove compartment (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-244361-S15926577782006092100000) ).
6. Remove the adhesive polyurethane (3) covering the evaporator pipe. (See «ADHESIVE POLYURETHANE (3) ASSEMBLY NOTE»(ref-244331-S05828414432006092100000) ). CAUTION: Being careful not to damage the adhesive sponge rubber, remove adhesive polyurethane completely.
7. Remove the adhesive polyurethane (4). (See «ADHESIVE POLYURETHANE (4) ASSEMBLY NOTE»(ref-244331-S36255377492006092100000) ).
8. Remove the bolt and shift the evaporator pipe. Do not allow compressor oil to spill.
9. Remove the adhesive polyurethane (5). (See «ADHESIVE POLYURETHANE (5) ASSEMBLY NOTE»(ref-244331-S03562469662006092100000) ).
10. Remove the expansion valve. Do not allow compressor oil to spill.
11. Install in the reverse order of removal.
12. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-244391-S16318538802006092100000) ).

Scheme 22

1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
2. Disconnect the negative battery cable.
3. Remove the cover. (Scheme 22)
4. Disconnect the evaporator temperature sensor connector.
5. Disconnect the power MOSFET connector. (Full-auto air conditioner)
6. Remove in the order indicated in the table in the figure.
7. Install in the reverse order of removal.

Airflow Mode Main Link Installation Note

Scheme 23

Scheme 24

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 25

1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
2. Disconnect the negative battery cable.
3. Remove the following parts: Front seat (See «FRONT SEAT REMOVAL/INSTALLATION»(ref-244372-S00947186262006092100000) ). Center console (See «CENTER CONSOLE REMOVAL/INSTALLATION»(ref-244361-S27977397232006092100000) ). Front scuff plate inner (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-244361-S26008392432006092100000) ). Front side trim (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-244361-S28323081802006092100000) ). Side wall (See «SIDE WALL REMOVAL/INSTALLATION»(ref-244361-S31703119622006092100000) ). Shift lever component (MTX) (See «MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION»(ref-244380-S36947017532006092100000) ). Selector lever component (ATX) (See «SELECTOR LEVER COMPONENT REMOVAL/INSTALLATION»(ref-244377-S02725560272006092100000) ). Front console (See «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-244361-S03102331672006092100000) ). Dust cover (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION»(ref-244338-S20307144292006092100000) ).
4. Partially open the floor covering. (See «FLOOR COVERING REMOVAL/INSTALLATION»(ref-244361-S38648091892006092100000) ).
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.

Scheme 26

1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
2. Disconnect the negative battery cable.
3. Discharge the refrigerant. (See «REFRIGERANT CHARGING»(ref-244391-S42129033012006092100000) ).
4. Remove the splash shield.
5. Remove the A/C drive belt. (See «DRIVE BELT REPLACEMENT [L3]»(ref-244325-S01328208652006092100000) ).
6. Detach the two wiring harness clamps.
7. Disconnect the cooler hose (LO) and cooler hose (HI). Do not allow remaining compressor oil in the refrigerant line to spill. (See «REFRIGERANT LINES REMOVAL/INSTALLATION»(ref-244331-S03928268132006092100000) ). 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.
8. Remove the A/C compressor protector.
9. Remove in the order indicated in the table. 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.
10. Install in the reverse order of removal.
11. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-244391-S16318538802006092100000) ).

A/C Compressor Installation Note

Scheme 27

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. A/C compressor oil type ATMOS GU10 A/C compressor oil sealed volume (approx. quantity) 160 ml {160 cc, 5.41 fl oz}

Scheme 28

1. Discharge the refrigerant. (See «REFRIGERANT CHARGING»(ref-244391-S42129033012006092100000) ).
2. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
3. Disconnect the negative battery cable.
4. Remove the under cover.
5. Remove the cooling fan component. (See «FAN MOTOR REMOVAL/INSTALLATION [L3]»(ref-244337-S04115688722006092100000) ).
6. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [L3]»(ref-244337-S29195014592006092100000) ).
7. Remove the air cleaner. (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION [L3]»(ref-244332-S08851886592006092100000) ).
8. Remove the front bumper. (See «FRONT BUMPER REMOVAL/INSTALLATION»(ref-244342-S11707177962006092100000) ).
9. Disconnect the cooler pipe and cooler hose (HI). Do not allow remaining compressor oil in the refrigerant line 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.
10. Remove the radiator upper mount.
11. Remove the rubber plate between radiator and shroud.
12. Disconnect the radiator hose from the radiator.
13. Remove the radiator with the condenser installed. (See «RADIATOR REMOVAL/INSTALLATION [L3]»(ref-244337-S03703928432006092100000) ).
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-244331-S07454802052006092100000) ). 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-244391-S16318538802006092100000) ).

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 29

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 30

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.