Basic System (HVAC): Removal & Installation Mazda 6 GJ

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 76

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 76): A/C Unit Components With Torque Specifications

Scheme 77

1. Assemble the evaporator temperature sensor as shown in the figure. (Scheme 77): Identifying Evaporator Temperature Sensor Dimension

Scheme 78

Scheme 79

Scheme 80

Scheme 81

1. Remove the cover. (Scheme 78): Heater Pipe Cover And Screw
2. Remove the bracket and cover. (Scheme 79): Bracket And Cover
3. Remove the bolt and pull the heater pipe outward and remove it. (Scheme 80): Heater Pipe Outward And Bolt
4. Remove the heater pipe and pull the heater core outward and remove it. (Scheme 81): Pulling Heater Core Outward

Scheme 82

Scheme 83

1. Set assemble heater pipes as shown in the figure and then set it to the heater core. (Scheme 82): Heater Pipes
2. Install the bracket and cover. (Scheme 83): Bracket And Cover

Scheme 84

1. Disconnect the negative battery cable.
2. Discharge the refrigerant. (See «REFRIGERANT CHARGING»(ref-581662-S18980350532013101400000).) 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-581666-S32619594172013101400000).)
4. Remove the expansion valve. Do not allow compressor oil to spill. (Scheme 84): Expansion Valve And Bolts With Torque Specification
5. Install in the reverse order of removal.
6. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-581662-S05846877252013101400000).)

A/C Compressor Installation Note

Scheme 85

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 85): Draining A/C Compressor Oil A/C compressor oil type ZXL 100PG A/C compressor oil sealed volume (approx. quantity) 120 ml {120 cc, 4.06 fl oz}

Scheme 86

1. Disconnect the negative battery cable.
2. Discharge the refrigerant. (See «REFRIGERANT CHARGING»(ref-581662-S18980350532013101400000).)
3. Remove the aerodynamic under cover No.1. (See «AERODYNAMIC UNDER COVER NO.1 REMOVAL/INSTALLATION»(ref-581657-S31409051752013101400000).)
4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.5]»(ref-581646-S28004987162013101400000).)(See «ENGINE COOLANT REPLACEMENT [MZI 3.7 V6]»(ref-581683-S26168476562013101400000).)
5. Disconnect the cooler hose LO and cooler hose HI. (See «REFRIGERANT LINE REMOVAL/INSTALLATION»(ref-581666-S32619594172013101400000).)
6. Remove the air cleaner, air hose and fresh air duct component. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581679-S24618371532013101400000).) (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-581645-S06665670962013101400000).)
7. Remove the coolant reserve tank. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 2.5]»(ref-581646-S37465899902013101400000).)
8. Remove the cooling fan component. (See «COOLING FAN MOTOR REMOVAL/INSTALLATION [MZR 2.5]»(ref-581646-S06325450512013101400000).) (See «COOLING FAN MOTOR REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581683-S04818170622013101400000).)
9. Disconnect the ATF oil cooler hose from the radiator. (ATX) (See «OIL COOLER REMOVAL/INSTALLATION [AY6A-EL]»(ref-581676-S31177358192013101400000).)
10. Remove the radiator. (See «RADIATOR REMOVAL/INSTALLATION [MZR 2.5]»(ref-581646-S25697810412013101400000).) (See «RADIATOR REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581683-S23937620922013101400000).)
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. (Scheme 86): Condenser, Radiator Bolts With Torque Specification
12. Install in the reverse order of removal.
13. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 2.5]»(ref-581646-S26582918502013101400000).) (See «ENGINE COOLANT LEAKAGE INSPECTION [MZI 3.7 V6]»(ref-581683-S19761424272013101400000).)
14. Inspect the ATF level. (ATX) (See «AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION [FS5A-EL]»(ref-581660-S08068979012013101400000).)
15. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-581662-S05846877252013101400000).)

Scheme 87

Scheme 88

Scheme 89

1. Align the bracket groove of the condenser to the radiator positioning rib. (Scheme 87): Aligning Bracket Groove Of Condenser To Radiator Positioning Rib
2. Align the bracket notch of the condenser to the radiator positioning rib. (Scheme 88): Aligning Bracket Notch Of Condenser To Radiator Positioning Rib
3. Install the condenser installation bolts as shown in the figure. (Scheme 89): Condenser Installation Bolts With Torque Specification
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}

Refrigerant Line Installation Note

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

Scheme 90

1. Tighten the bolt of joint by hand. (Scheme 90): Installing Refrigerant Line Connection Bolt
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 with a torque wrench.