Basic System (HVAC): Removal & Installation Mazda 6 GH рестайлинг

AIR FILTER REMOVAL/INSTALLATION

1. Remove the glove compartment. (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-448656-S36262450112012012000000) .)
2. Remove in the order indicated in the table. PARTS DESCRIPTION CHART 1 Air filter cover 2 Air filter
3. Install in the reverse order of removal.

Scheme 78

A/C Unit Installation Note

1. When installing a new A/C unit or evaporator, add compressor oil to the refrigerant cycle. Supplemental amount (approx. quantity) 35 ml {35 cc, 1.2 fl oz}

Scheme 79

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. PARTS DESCRIPTION CHART 1 Air intake actuator 2 Driver's side air mix actuator (Full-auto air conditioner) 3 Side heat duct (LH) 4 Polyurethane form (1) 5 Air filter cover 6 Air filter 7 Blower case (1) 8 Blower case (2) 9 Air intake door 10 Blower motor 11 Bracket 12 Bracket 13 Polyurethane form (2) 14 Plate cover 15 Resistor (Manual air conditioner) 16 Front power MOS FET (Full-auto air conditioner) 17 Evaporator 18 Heater core (See «HEATER PIPE REMOVAL NOTE»(ref-448620-S26743017002012012000000) .) (See «HEATER PIPE INSTALLATION NOTE»(ref-448620-S20250508082012012000000) .) 19 Side heat duct (RH) 20 Passenger's side air mix actuator (Full-auto air conditioner) Air mix actuator (Manual air conditioner) 21 Airflow mode actuator 22 Airflow mode link set 23 A/C case (1) 24 Evaporator temperature sensor (See «EVAPORATOR TEMPERATURE SENSOR ASSEMBLY NOTE»(ref-448620-S27299010592012012000000) .) 25 A/C case (2) 26 Polyurethane form (3) 27 Air hose (Full-auto air conditioner) 28 Sub harness 29 A/C case (3) 30 Air mix door (LH) 31 Air flow mode door (LH) 32 Baffle (LH) 33 A/C case (4) 34 Air mix door (RH) 35 Airflow mode door (RH) 36 Baffle RH 37 Divider

Scheme 80

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

Scheme 81

Scheme 82

1. Remove the cover.
2. Remove the bracket and cover.
3. Remove the bolt and pull the heater pipe outward and remove it.
4. Remove the heater pipe and pull the heater core outward and remove it.

Scheme 83

Scheme 84

1. Set assemble heater pipes as shown in the illustration and then set it to the heater core.
2. Install the bracket and cover.

Scheme 85

Scheme 86

1. Disconnect the negative battery cable.
2. Discharge the refrigerant. (See «REFRIGERANT CHARGING»(ref-448617-S14847403472012012000000) .) 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 pipe and cooler hose from the A/C unit. (See «REFRIGERANT LINE REMOVAL/INSTALLATION»(ref-448620-S23474466362012012000000) .)
4. Remove the expansion valve. Do not allow compressor oil to spill.
5. Install in the reverse order of removal.
6. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-448617-S42234570072012012000000) .)

REAR HEAT DUCT COMPONENT REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.
2. Remove the following parts: Front seats (See «FRONT SEAT REMOVAL/INSTALLATION»(ref-448628-S07156841762012012000000) .) Front scuff plates (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-448656-S42845656582012012000000) .) Front side trims (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-448656-S24645152862012012000000) .) Steering shaft cover (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITHOUT ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-448619-S01292366382012012000000) .) (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITH ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-448619-S18771656912012012000000) .) Upper panel (See «UPPER PANEL REMOVAL/INSTALLATION»(ref-448656-S41204061692012012000000) .) Decoration panel (See «DECORATION PANEL REMOVAL/INSTALLATION»(ref-448656-S12186936852012012000000) .) Shift knob (MTX) (See «MANUAL TRANSAXLE SHIFT MECHANISM LOCATION INDEX»(ref-448657-S31582424492012012000000) .) Shift panel (See «SHIFT PANEL REMOVAL/INSTALLATION»(ref-448656-S21764171192012012000000) .) Center panel lower (See «CENTER PANEL LOWER REMOVAL/INSTALLATION»(ref-448656-S13809786282012012000000) .) Rear console (See «REAR CONSOLE REMOVAL/INSTALLATION»(ref-448656-S24311442192012012000000) .) Fuel-filler lid opener bezel (See «FUEL-FILLER LID OPENER BEZEL REMOVAL/INSTALLATION»(ref-448656-S05403168622012012000000) .)
3. Turn the floor covering over. (See «FLOOR COVERING REMOVAL/INSTALLATION»(ref-448656-S18115163062012012000000) .)
4. Remove in the order indicated in the table. PARTS DESCRIPTION CHART 1 Fastener 2 Rear heat duct (RH) 3 Rear heat duct (LH)
5. Install in the reverse order of removal.

Scheme 87

REAR VENT DUCT COMPONENT REMOVAL/INSTALLATION [Arab Gulf Cooperation Council]

1. Disconnect the negative battery cable.
2. Remove the rear console. (See «REAR CONSOLE REMOVAL/INSTALLATION»(ref-448656-S24311442192012012000000) .)
3. Remove the rear vent duct. PARTS DESCRIPTION CHART 1 Fastener 2 Rear vent duct (2) 3 Rear vent duct (1)
4. Install in the reverse order of removal.

Scheme 88

Scheme 89

Scheme 90

Scheme 91

1. Disconnect the negative battery cable.
2. Discharge the refrigerant. (See «REFRIGERANT CHARGING»(ref-448617-S14847403472012012000000) .)
3. Remove the front under cover.
4. Remove the drive belt. (See «DRIVE BELT INSPECTION [MZR 2.5]»(ref-448577-S08865407892012012000000) .) (See «DRIVE BELT INSPECTION [MZI 3.7 V6]»(ref-448598-S07582627582012012000000) .)
5. Remove the 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 in the order indicated in the table. Do not allow compressor oil to spiff. MZR 2.5 MZI 3.7 V6 PARTS DESCRIPTION CHART 1 Cooler hose (LO) (See «REFRIGERANT LINE REMOVAL/INSTALLATION»(ref-448620-S23474466362012012000000) .) 2 Cooler hose (HI) (See «REFRIGERANT LINE REMOVAL/INSTALLATION»(ref-448620-S23474466362012012000000) .) 3 A/C compressor connector 4 A/C compressor (See «A/C COMPRESSOR INSTALLATION NOTE»(ref-448620-S10921633812012012000000) .)
7. Install in the reverse order of removal.
8. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-448617-S42234570072012012000000) .)

A/C Compressor Installation Note

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

ZXL 100PG

A/C compressor oil sealed volume (approx. quantity)

120 ml {120 cc, 4.06 fl oz}

Scheme 92

CONDENSER REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.
2. Discharge the refrigerant. (See «REFRIGERANT CHARGING»(ref-448617-S14847403472012012000000) .)
3. Remove the aerodynamic under cover No. 1. (See «AERODYNAMIC UNDER COVER NO. 1 REMOVAL/INSTALLATION»(ref-448621-S27173632662012012000000) .)
4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.5]»(ref-448580-S03220346392012012000000) .) (See «ENGINE COOLANT REPLACEMENT [MZI 3.7 V6]»(ref-448600-S26116776422012012000000) .)
5. Disconnect the cooler hose LO and cooler hose HI. (See «REFRIGERANT LINE REMOVAL/INSTALLATION»(ref-448620-S23474466362012012000000) .)
6. Remove the air cleaner, air hose and fresh air duct component. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-448605-S22810089552012012000000) .) (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-448579-S21051015612012012000000) .)
7. Remove the coolant reserve tank. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 2.5]»(ref-448580-S11651142292012012000000) .)
8. Remove the cooling fan component. (See «COOLING FAN MOTOR REMOVAL/INSTALLATION [MZR 2.5]»(ref-448580-S07120384462012012000000) .) (See «COOLING FAN MOTOR REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-448600-S28285806762012012000000) .)
9. Disconnect the ATF oil cooler hose from the radiator. (ATX) (See «OIL COOLER REMOVAL/INSTALLATION [AY6A-EL]»(ref-448627-S16251442042012012000000) .)
10. Remove the radiator. (See «RADIATOR REMOVAL/INSTALLATION [MZR 2.5]»(ref-448580-S22697648042012012000000) .) (See «RADIATOR REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-448600-S40757394132012012000000) .)
11. Remove the condenser from the radiator. 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.
12. Install in the reverse order of removal.
13. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 2.5]»(ref-448580-S05051878482012012000000) .) (See «ENGINE COOLANT LEAKAGE INSPECTION [MZI 3.7 V6]»(ref-448600-S04552116222012012000000) .)
14. Inspect the ATF level. (ATX) (See «AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION [FS5A-EL]»(ref-448615-S34844211352012012000000) .)
15. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-448617-S42234570072012012000000) .)

Scheme 93

Scheme 94

1. Align the bracket groove of the condenser to the radiator positioning rib.
2. Align the bracket notch of the condenser to the radiator positioning rib.
3. Install the condenser installation bolts as shown in the illustration.
4. When installing a new condenser, add compressor oil to the refrigerant cycle. Supplemental amount (approx. quantity) 30 ml {30 cc, 1.0 fl oz}

RECEIVER/DRIER REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.
2. Drain the refrigerant. (See «REFRIGERANT CHARGING»(ref-448617-S14847403472012012000000) .)
3. Remove the front bumper. (See «FRONT BUMPER REMOVAL/INSTALLATION»(ref-448631-S32376246232012012000000) .) 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. Remove in the order indicated in the table. Do not allow compressor oil to spill. PARTS DESCRIPTION CHART 1 Bolt 2 Receiver/drier (See «RECEIVER/DRIER REMOVAL NOTE»(ref-448620-S35277287422012012000000) .) (See «RECEIVER/DRIER INSTALLATION NOTE»(ref-448620-S30062009572012012000000) .)
5. Install in the reverse order of removal.
6. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-448617-S42234570072012012000000) .)

Scheme 95

Receiver/Drier Removal Note

1. Disconnect the block joint type pipes by grasping female side of the block with hand holding firmly, then loosen the connection bolt.

Scheme 96

Receiver/Drier Installation Note

1. Tighten the bolt of joint by hand.
2. Tighten the joint to the specified torque. Connect the block joint type pipe by grasping female side of the block with hand holding firmly, then tighten the connection bolt.

Scheme 97

Scheme 98

1. Disconnect the negative battery cable.
2. Remove the engine coolant tank. ((See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 2.5]»(ref-448580-S05051878482012012000000) .) (See «ENGINE COOLANT LEAKAGE INSPECTION [MZI 3.7 V6]»(ref-448600-S04552116222012012000000) .)
3. Discharge the refrigerant. (See «REFRIGERANT CHARGING»(ref-448617-S14847403472012012000000) .)
4. Disconnect the refrigerant pressure sensor connector.
5. Remove the No. 3 engine mount earth.
6. Do not allow remaining compressor oil in the piping and connecting parts to spill, and remove in the order indicated in the table. 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. Install in the reverse order of removal.
8. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-448617-S42234570072012012000000) .) PARTS DESCRIPTION CHART 1 Cooler pipe (See «REFRIGERANT LINE REMOVAL NOTE»(ref-448620-S34827145262012012000000) .) (See «REFRIGERANT LINE INSTALLATION NOTE»(ref-448620-S33065133672012012000000) .) 2 Cooler hose (See «REFRIGERANT LINE REMOVAL NOTE»(ref-448620-S34827145262012012000000) .) (See «REFRIGERANT LINE INSTALLATION NOTE»(ref-448620-S33065133672012012000000) .) 3 Cooler hose (LO) (See «REFRIGERANT LINE REMOVAL NOTE»(ref-448620-S34827145262012012000000) .) (See «REFRIGERANT LINE INSTALLATION NOTE»(ref-448620-S33065133672012012000000) .) 4 Cooler hose (HI) (See «REFRIGERANT LINE REMOVAL NOTE»(ref-448620-S34827145262012012000000) .) (See «REFRIGERANT LINE INSTALLATION NOTE»(ref-448620-S33065133672012012000000) .)

Scheme 99

1. Remove the battery and battery tray. (See «BATTERY REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-448609-S21137111942012012000000) .)
2. Remove the engine cover (See «ENGINE COVER REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-448598-S36488820422012012000000) .)
3. Remove the coolant reserve tank. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-448600-S26159090622012012000000) .)
4. Discharge the refrigerant. (See «REFRIGERANT CHARGING»(ref-448617-S14847403472012012000000) .)
5. Disconnect the refrigerant pressure sensor connector.
6. Remove the No. 3 engine mount ground.
7. Remove the following parts. Windshield wiper arm and blade (See «WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION»(ref-448630-S30982890692012012000000) .) Cowl grille (See «COWL GRILLE REMOVAL/INSTALLATION»(ref-448621-S18876419092012012000000) .) Windshield wiper motor (See «WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION»(ref-448630-S42273392972012012000000) .) Cowl panel (See «COWL PANEL REMOVAL/INSTALLATION»(ref-448631-S27188386092012012000000) .) DSC HU/CM (with DSC) (See «DSC HU/CM REMOVAL/INSTALLATION»(ref-448644-S17012199952012012000000) .) Front pipe (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-448626-S36333721212012012000000) .) Air cleaner component (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-448605-S22810089552012012000000) .) Aerodynamic under cover No. 1 and No. 2. (See «AERODYNAMIC UNDER COVER NO. 1 REMOVAL/INSTALLATION»(ref-448621-S27173632662012012000000) .) (See «AERODYNAMIC UNDER COVER NO. 2 REMOVAL/INSTALLATION»(ref-448621-S11343791992012012000000) .)
8. Disconnect the engine mount No. 1. (See «ENGINE REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-448598-S02384560842012012000000) .)
9. Sustain the engine and transaxle component with the engine jack.
10. Disconnect the engine mount No. 3 and No. 4. (See «ENGINE REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-448598-S02384560842012012000000) .)
11. Move the engine and transaxle component slightly direction to left, and enlarge the space for remove the refrigerant line.
12. Do not allow remaining compressor oil in the piping and connecting parts to spill, and remove in the order indicated in the table. 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. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-448617-S42234570072012012000000) .) PARTS DESCRIPTION CHART 1 Cooler pipe (See «REFRIGERANT LINE REMOVAL NOTE»(ref-448620-S34827145262012012000000) .) (See «REFRIGERANT LINE INSTALLATION NOTE»(ref-448620-S33065133672012012000000) .) 2 Cooler hose (See «REFRIGERANT LINE REMOVAL NOTE»(ref-448620-S34827145262012012000000) .) (See «REFRIGERANT LINE INSTALLATION NOTE»(ref-448620-S33065133672012012000000) .) 3 Cooler hose (LO) (See «REFRIGERANT LINE REMOVAL NOTE»(ref-448620-S34827145262012012000000) .) (See «REFRIGERANT LINE INSTALLATION NOTE»(ref-448620-S33065133672012012000000) .) 4 Cooler hose (HI) (See «REFRIGERANT LINE REMOVAL NOTE»(ref-448620-S34827145262012012000000) .) (See «REFRIGERANT LINE INSTALLATION NOTE»(ref-448620-S33065133672012012000000) .)

Scheme 100

1. Disconnect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly, and then remove the connection bolt.

Refrigerant Line Installation Note

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