Control System - HVAC (Full Auto Air Conditioner): Removal & Installation Mazda 6 GJ

A/C Compressor Pulley Installation Note

Scheme 39

1. Install the inner wheel of the pulley using a press and SST (49 B034 212) to the compressor. (Scheme 39): Installing Inner Wheel Of Pulley Substitution SST 49 B034 212 Outer diameter: 48 mm {1.9 in} or less Inner diameter: 36 mm {1.4 in} or more Plate thickness: 1 mm {0.04 in} or more Height: 30 mm {1.2 in} or more

Scheme 40

1. First, insert the 1 mm {0.039 in} thick shim into the shaft. (Scheme 40): Shim And Shaft

Scheme 41

Scheme 42

1. Measure the clearance around the entire circumference between the pressure plate and A/C compressor pulley using a thickness gauge. (Scheme 41): Measuring Pressure Plate And A/C Compressor Pulley Clearance
2. Verify that the clearance. (Scheme 42): A/C Compressor And Shim If not within the specification, remove the pressure plate and adjust the clearance by changing the shim or the number of shims. Magnetic clutch clearance 0.3-0.6 mm {0.012-0.023 in}

Scheme 43

1. Connect battery to terminal A of magnetic clutch and ground to A/C compressor body. (Scheme 43): Battery To Terminal A Of Magnetic Clutch And Ground To A/C Compressor Body
2. Verify that the magnetic clutch operates. If there is any malfunction, replace the magnetic clutch.

Scheme 44

1. Disconnect the negative battery cable.
2. Remove the driver's side lower panel. (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-581614-S08723493922013101400000).) 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.
3. Remove in the order indicated in the table. (Scheme 44): Solar Radiation Sensor And Connector
4. Install in the reverse order of removal.

Scheme 45

1. Shine a filament light or expose the solar radiation sensor to natural sunlight.
2. Connect the positive (+) lead to terminal B, C and negative (-) lead to terminal A of the solar radiation, and verify that the voltage value is output. (Scheme 45): Inspecting Solar Radiation Sensor (Full-Auto Air Conditioner) If the voltage is 0 V, replace the solar radiation sensor.

Scheme 46

1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Remove in the order indicated in the table. (Scheme 46): Ambient Temperature Sensor And Connector
4. Install in the reverse order of removal.

Scheme 47

1. Measure the temperature around the ambient temperature sensor and measure the resistance between the ambient temperature sensor terminal. (Scheme 47): Ambient Temperature Sensor Graph If the characteristics of the ambient temperature sensor are not as shown in the graph, replace the ambient temperature sensor.

Scheme 48

1. Disconnect the negative battery cable.
2. Remove the driver's side lower panel. (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-581614-S08723493922013101400000).)
3. Remove the order indicated in the table. (Scheme 48): Passenger Compartment Temperature Sensor, Hose And Connector
4. Install in the reverse order of removal.

Scheme 49

1. Measure the temperature around the passenger compartment temperature sensor and measure the resistance between passenger compartment temperature sensor terminal. (Scheme 49): Passenger Compartment Temperature Sensor Resistance Graph 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 [FULL-AUTO AIR CONDITIONER]

1. Remove the evaporator temperature sensor from the A/C unit. (See «A/C UNIT DISASSEMBLY/ASSEMBLY»(ref-581666-S39152968662013101400000) .)

Scheme 50

1. Set the fan speed MAX HI.
2. Set the temperature control at MAX COLD (Turn the left).
3. Turn the A/C switch off.
4. Set the RECIRCULATE mode.
5. Close all doors and windows.
6. Wait for 5 min.
7. Remove the glove compartment. (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-581614-S35474389282013101400000).)
8. Disconnect the evaporator temperature sensor connector. (See «EVAPORATOR TEMPERATURE SENSOR REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER]»(ref-581663-S23513318502013101400000).)
9. Measure the temperature at the blower inlet.
10. Measure the resistance between terminals of the evaporator temperature sensor. (Scheme 50): Evaporator Temperature Sensor Resistance Graph If the resistance is not as shown in the graph, replace the evaporator temperature sensor.

Scheme 51

1. Disconnect the negative battery cable.
2. Remove the coolant reserve tank. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 2.5]»(ref-581646-S37465899902013101400000).) (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581683-S13045309552013101400000).)
3. Collect the refrigerant. (See «REFRIGERANT CHARGING»(ref-581662-S18980350532013101400000).)
4. Disconnect the refrigerant pressure sensor connector. 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.
5. Loosen the refrigerant pressure sensor using two spanners.
6. Remove the refrigerant pressure sensor. (See «REFRIGERANT PRESSURE SENSOR INSTALLATION NOTE»(ref-581663-S10168524832013101400000).) (Scheme 51): Refrigerant Pressure Sensor Tightening torque 5.5-8.1 N.m {52-82 kgf.cm, 49-71 in.lbf}
7. Install in the reverse order of removal.
8. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-581662-S05846877252013101400000).)

Refrigerant Pressure Sensor Installation Note

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

Scheme 52

Scheme 53

1. Install the manifold gauge.
2. Verify the high-pressure side reading of the manifold gauge.
3. Measure the terminal voltage of the PCM. 1AR, 1J or 1AE (MZR 2.5) 1AT, 1M or 1BJ (MZI 3.7 V6)
4. Verify that below graph as measure the terminal voltage 1J (MZR 2.5), 1M (MZI 3.7 V6).
5. Follow the PCM inspection when measure the other terminal voltage. (See «PCM INSPECTION [MZR 2.5]»(ref-581641-S02967527962013101400000).) (See «PCM INSPECTION [MZI 3.7 V6]»(ref-581669-S17071525992013101400000).) Terminal 1AR (MZR 2.5), 1AT (MZI 3.7 V6): 1.0 V or less Terminal 1AE (MZR 2.5), 1BJ (MZI 3.7 V6): Approx. 5 V (Ignition switch on) If the each voltage is not normal, inspect the related wiring harness. If there is any malfunction, replace the related wiring harness. If wiring harness is normal, replace the refrigerant pressure sensor. (Scheme 52): Refrigerant Pressure Sensor Connector Terminals (MZR 2.5) (Scheme 53): Refrigerant Pressure Sensor Connector Terminals (MZI 3.7 V6)

Scheme 54

1. Disconnect the negative battery cable.
2. Remove the following parts: Upper panel (See «UPPER PANEL REMOVAL/INSTALLATION»(ref-581614-S15065956352013101400000).) Decoration panel (See «DECORATION PANEL REMOVAL/INSTALLATION»(ref-581614-S30597239632013101400000).) Shift lever knob (MTX) (See «MANUAL TRANSAXLE SHIFT MECHANISM LOCATION INDEX»(ref-581615-S41865543102013101400000).) Shift panel (See «SHIFT PANEL REMOVAL/INSTALLATION»(ref-581614-S38776581642013101400000).) Center panel lower (See «CENTER PANEL LOWER REMOVAL/INSTALLATION»(ref-581614-S05740589362013101400000).)
3. Remove in the order indicated in the table. (Scheme 54): Climate Control Unit Connector And Screws
4. Disconnect the climate control unit connectors and remove the climate control unit.
5. Install in the reverse order of removal.