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

BLOWER MOTOR REMOVAL

Note. The blower motor is located on the A/C unit as shown in the figure.

Scheme 73

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Scheme 78

1. Set the air intake mode to FRESH.
2. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
3. Disconnect the negative battery cable.
4. Remove the following parts: 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) ). Front scuff plate inner (passenger's side) (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-244361-S26008392432006092100000) ). Front side trim (passenger's side) (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-244361-S28323081802006092100000) ). Side panel (passenger's side) (See «SIDE PANEL REMOVAL/INSTALLATION»(ref-244361-S16170239572006092100000) ). Glove compartment (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-244361-S15926577782006092100000) ). Car-navigation unit (See «CAR-NAVIGATION UNIT REMOVAL/INSTALLATION»(ref-244348-S37944843702006092100000) ). Hood release lever (See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-244349-S20261737812006092100000) ). Lower panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-244361-S09707910472006092100000) ). Airflow mode actuator (See «AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION»(ref-244390-S38121444932006092100000) ).
5. Remove the BCM wiring harness grommets.
6. Set the car-navigation unit wiring harness out of the way to secure the operation space.
7. Remove the screws shown in the figure and slide the blower case. CAUTION: Slide the blower case while pressing the dashboard insulator, otherwise the blower case could be damaged.
8. Disconnect the air intake actuator connector.
9. Remove the blower case shown in the figure.
10. Remove the air guide.
11. Install the SST (49 B061 015) to the blower motor. (See «SST INSTALLATION NOTE»(ref-244390-S03930520342006092100000) ).
12. Disconnect the blower motor cooling pipe connected to the blower motor.
13. Disconnect the blower motor connector as shown in the figure.
14. Remove the blower motor cover. (See «BLOWER MOTOR COVER REMOVAL NOTE»(ref-244390-S10432316362006092100000) ). 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-244390-S11562920022006092100000) ).

Scheme 79

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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.

Blower Motor Removal Note

Scheme 83

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Scheme 85

1. Install the SST to the blower motor. (See «SST INSTALLATION NOTE»(ref-244390-S03930520342006092100000) ).
2. Install the blower motor with the SST (49 B061 015) installed, to the A/C unit. (See «BLOWER MOTOR INSTALLATION NOTE»(ref-244390-S23573386052006092100000) ).
3. Install the blower motor cover from the driver's side. (See «BLOWER MOTOR COVER INSTALLATION NOTE»(ref-244390-S28320806782006092100000) ).
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 air guide. CAUTION: Install the blower case while pressing the dashboard insulator, otherwise the blower case could be damaged.
8. Temporarily install the blower case. (See «BLOWER CASE INSTALLATION NOTE»(ref-244390-S12131413522006092100000) ).
9. Connect the air intake actuator connector.
10. Install the blower case.
11. Install the following parts: Airflow mode actuator (See «AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION»(ref-244390-S38121444932006092100000) ). Lower panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-244361-S09707910472006092100000) ). Hood release lever (See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-244349-S20261737812006092100000) ). BCM harness grommet Car-navigation unit (See «CAR-NAVIGATION UNIT REMOVAL/INSTALLATION»(ref-244348-S37944843702006092100000) ). Glove compartment (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-244361-S15926577782006092100000) ). Side panel (passenger's side) (See «SIDE PANEL REMOVAL/INSTALLATION»(ref-244361-S16170239572006092100000) ). Front side trim (passenger's side) (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-244361-S28323081802006092100000) ). Front scuff plate (passenger's side) (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-244361-S26008392432006092100000) ). Front console (See «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-244361-S03102331672006092100000) ). Selector lever component (ATX) (See «SELECTOR LEVER COMPONENT REMOVAL/INSTALLATION»(ref-244377-S02725560272006092100000) ). Shift lever component (MTX) (See «MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION»(ref-244380-S36947017532006092100000) ). Side wall (See «SIDE WALL REMOVAL/INSTALLATION»(ref-244361-S31703119622006092100000) ).
12. Connect the negative battery cable.
13. Install the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).

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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Scheme 91

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. Insert the blower case in the direction shown in the figure.
4. Install the blower case by inserting and rotating it in the directions of the arrows shown in the figure.

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 92

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 93

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 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 98

1. Remove the battery cover.
2. Disconnect the negative battery cable.
3. Pry the solar radiation sensor from the dashboard using a flathead screwdriver wrapped with protective tape.
4. 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.
5. Install in the reverse order of removal.

Scheme 99

1. Shine an incandescent light ( approx. 60 W ) directly on the solar radiation sensor from approx. 100 mm {3.9 in}.
2. Using a tester, connect the positive (+) lead to solar radiation sensor terminal A, the negative (-) lead to terminal B and verify that the output voltage is approx. 0.45 V. If the voltage is not normal, replace the solar radiation sensor.

Scheme 100

1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
2. Disconnect the negative battery cable.
3. Remove the under cover.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.

Scheme 101

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 102

1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
2. Disconnect the negative battery cable.
3. Remove the following parts: 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) ). Front scuff plate inner (passenger's side) (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-244361-S26008392432006092100000) ). Front side trim (passenger's side) (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-244361-S28323081802006092100000) ). Side panel (passenger's side) (See «SIDE PANEL REMOVAL/INSTALLATION»(ref-244361-S16170239572006092100000) ). Glove compartment (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-244361-S15926577782006092100000) ).
4. Remove the air hose.
5. Disconnect the passenger compartment temperature sensor connector.
6. Insert a tape-wrapped flathead screwdriver into the convex part of the passenger compartment temperature sensor and pry it to remove the passenger compartment temperature sensor together with passenger compartment temperature sensor holder.
7. Remove the passenger compartment temperature sensor.
8. Install in the reverse order of removal.

Scheme 103

1. Measure the temperature around the passenger compartment temperature sensor and measure the resistance between passenger compartment temperature sensor terminals A and B. If the characteristics of the passenger compartment temperature sensor are not as shown in the graph, 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-244331-S28921759552006092100000) ).

Refrigerant Pressure Switch Installation Note

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

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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 B and C, A and D. If there is any malfunction, replace the refrigerant pressure switch.

Scheme 107

1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
2. Disconnect the negative battery cable.
3. Remove the following parts: 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) ).
4. Remove the center panel unit. (See «CENTER PANEL UNIT REMOVAL/INSTALLATION»(ref-244348-S26058616022006092100000) ).
5. Release the left and right tabs and remove as shown in the figure.
6. Install in the order of removal.

Scheme 108

Scheme 109

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 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) ). Hood release lever (See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-244349-S20261737812006092100000) ). Glove compartment (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-244361-S15926577782006092100000) ). Lower panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-244361-S09707910472006092100000) ). Side panel (passenger's side) (See «SIDE PANEL REMOVAL/INSTALLATION»(ref-244361-S16170239572006092100000) ). Column cover (See «COLUMN COVER REMOVAL/INSTALLATION»(ref-244361-S33738517862006092100000) ).
4. Remove the center panel unit. (See «CENTER PANEL UNIT REMOVAL/INSTALLATION»(ref-244348-S26058616022006092100000) ).
5. Remove the clamp.
6. Remove the wire clamp with air mix wire and airflow mode wire from the A/C unit.
7. Release the left and right tabs and remove in the order indicated in the table.

Scheme 110

1. Remove the E-ring from wire clamp.
2. Slide the wire clamp in the direction shown in the figure and remove it.

Scheme 111

1. Install the wire clamp to A/C unit.
2. Install E-ring to each wire. (See «E-RING INSTALLATION NOTE»(ref-244390-S12758934252006092100000) ).
3. Pass each wire through the following routes and connect to A/C unit.
4. Connect the climate control unit connector, fan switch connector.
5. Install the climate control unit.
6. Connect each wire to A/C unit.
7. Install the center panel unit. (See «CENTER PANEL UNIT REMOVAL/INSTALLATION»(ref-244348-S26058616022006092100000) ).
8. Install the following parts: Column cover (See «COLUMN COVER REMOVAL/INSTALLATION»(ref-244361-S33738517862006092100000) ). Glove compartment (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-244361-S15926577782006092100000) ). Side panel (passenger's side) (See «SIDE PANEL REMOVAL/INSTALLATION»(ref-244361-S16170239572006092100000) ). Lower panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-244361-S09707910472006092100000) ). Hood release lever (See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-244349-S20261737812006092100000) ). Front console (See «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-244361-S03102331672006092100000) ). Selector lever component (ATX) (See «SELECTOR LEVER COMPONENT REMOVAL/INSTALLATION»(ref-244377-S02725560272006092100000) ). Shift lever component (MTX) (See «MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION»(ref-244380-S36947017532006092100000) ). Side wall (See «SIDE WALL REMOVAL/INSTALLATION»(ref-244361-S31703119622006092100000) ). Front side trim (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-244361-S28323081802006092100000) ). Front scuff plate inner (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-244361-S26008392432006092100000) ).
9. Connect the negative battery cable.
10. Install the battery cover.

Scheme 112

1. Install the wires as shown in the figure.