Basic HVAC System: Removal & Installation Mazda CX-5 I

A/C Unit Installation Note

1. When replacing the A/C unit or evaporator, add compressor oil to the refrigerant cycle. Supplemental oil amount (approx. quantity) 40 ml {40 cc, 1.4 fl oz}

Scheme 74

1. Install the clip as shown in the figure. (Scheme 74): Installing Drain Hose

Scheme 75

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 75): Disassembled View Of A/C Unit With Torque Specifications

Scheme 76

1. Assemble the evaporator temperature sensor as shown in the figure. (Scheme 76): Identifying Evaporator Temperature Sensor Installation Dimensions With Torque Specifications CAUTION: When installing the evaporator temperature sensor without replacing the evaporator, assemble the evaporator temperature sensor with the installation position slid to the left of the previous position by 1 line. If the evaporator temperature sensor is assembled to the previously installed position, it may not function due to poor contact of the fin surface with the sensor detection area caused by fin deformation. NOTE: If an evaporator temperature sensor cannot be correctly positioned on the evaporator, replace the evaporator.

Scheme 77

Scheme 78

Scheme 79

Scheme 80

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Discharge the refrigerant from the system. (See «REFRIGERANT CHARGING»(ref-615479-S35473472702014051000000) ). 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. Remove the nut.
4. Remove the clip.
5. Disconnect the refrigerant pressure sensor connector.
6. Disconnect the engine ground. (Scheme 77): Identifying Refrigerant Pressure Sensor Connector, Engine Ground, Nut And Clip With Torque Specifications
7. Remove the bolt and disconnect the cooler hose (LO) and cooler pipe. Do not allow compressor oil to spill. (Scheme 78): Identifying Cooler Hose (LO) And Cooler Pipe With Mounting Bolts And Torque Specifications
8. Set the cooler hose (LO) and cooler pipe aside as shown in the figure while being careful not to let remaining oil in the pipes to spill. CAUTION: When setting the cooler hose (LO) and cooler pipe aside, only bend the flexible part of the hose. If force is applied to areas other than the flexible hose, the pipe will bend and could be damaged. (Scheme 79): Setting Cooler Hose (LO) And Cooler Pipe
9. Remove the bolt.
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-615479-S38875091672014051000000) ). (Scheme 80): Identifying Expansion Valve With Mounting Bolts And Torque Specifications

Airflow Mode Main Link Installation Note

Scheme 81

Scheme 82

1. Align the airflow mode main link hole with the airflow mode sub link projection as shown in the figure. (Scheme 81): Aligning Airflow Mode Main Link Hole With Airflow Mode Sub Link Projection
2. Press the airflow mode main link lightly to the A/C unit, then set the projections of each airflow mode sub link into the grooves of the airflow mode main link.
3. Rotate airflow mode main link and verify that each mode is accessed properly. (Scheme 82): Rotating Airflow Mode Main Link

Scheme 83

Scheme 84

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Remove the following parts: Dashboard under cover (See «DASHBOARD UNDER COVER REMOVAL/INSTALLATION»(ref-615455-S39827127492014051000000) ). Side wall (See «SIDE WALL REMOVAL/INSTALLATION»(ref-615455-S29263037032014051000000) ). Glove compartment (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-615455-S15366383852014051000000) ).
3. Detach the tab and remove the front heat duct. LH (Scheme 83): Identifying Front Heat Duct (LH) RH (Scheme 84): Identifying Front Heat Duct (RH)
4. Install in the reverse order of removal.

Scheme 85

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Remove the following parts: Decoration panel (See «DECORATION PANEL REMOVAL/INSTALLATION»(ref-615455-S15150991172014051000000) ). Shift lever knob (MTX) (See «MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [C66M-R]»(ref-615440-S42122392892014051000000) ). Front console box (See «FRONT CONSOLE BOX REMOVAL/INSTALLATION»(ref-615455-S42371732362014051000000) ). Shift panel (See «SHIFT PANEL REMOVAL/INSTALLATION»(ref-615455-S00421900212014051000000) ). Upper panel (See «UPPER PANEL REMOVAL/INSTALLATION»(ref-615455-S24596820212014051000000) ). Rear console (See «REAR CONSOLE REMOVAL/INSTALLATION»(ref-615455-S26190969372014051000000) ). Side wall (See «SIDE WALL REMOVAL/INSTALLATION»(ref-615455-S29263037032014051000000) ). Front console (See «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-615455-S37957878882014051000000) ). Front scuff plate (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-615455-S15598834492014051000000) ). Front side trim (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-615455-S14137250292014051000000) ). Joint cover (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION»(ref-615435-S37273804732014051000000) ).
3. Turn the floor covering over.
4. Remove in the order indicated in the table. (Scheme 85): Identifying Rear Heat Duct And Fasteners
5. Install in the reverse order of removal.

Scheme 86

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Discharge the refrigerant. (See «REFRIGERANT CHARGING»(ref-615479-S35473472702014051000000) ).
3. Remove the front under cover No.2. (See «FRONT UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-615433-S21444705852014051000000) ).
4. Remove the drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S40242248072014051000000) ).
5. Disconnect the connector.
6. Remove bolts A. 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. Remove the cooler hose (LO). (See «REFRIGERANT LINE REMOVAL/INSTALLATION»(ref-615407-S04887267312014051000000) ).
8. Remove the cooler hose (HI). (See «REFRIGERANT LINE REMOVAL/INSTALLATION»(ref-615407-S04887267312014051000000) ).
9. Remove bolts B.
10. Remove the A/C compressor. Do not allow compressor oil to spill. (See «A/C COMPRESSOR INSTALLATION NOTE»(ref-615407-S03621943202014051000000) ).
11. Install in the reverse order of removal.
12. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-615479-S38875091672014051000000) ). (Scheme 86): Identifying A/C Compressor And Cooler Hoses With Mounting Bolts And Torque Specifications

A/C Compressor Installation Note

Scheme 87

1. Rotate the new A/C compressor shaft six to eight revolutions while pouring refrigerant oil in a clean measuring container. 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 pouring refrigerant oil in a separate, clean measuring container.
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 drained from the old A/C compressor back into the new A/C compressor. A/C compressor oil type FD46XG A/C compressor oil sealed volume (approx. quantity) 100 ml {100 cc, 3.38 fl oz} (Scheme 87): Comparing A/C Compressor Oil Amount

Scheme 88

Scheme 89

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Discharge the refrigerant. (See «REFRIGERANT CHARGING»(ref-615479-S35473472702014051000000) ).
3. Remove the front under cover No.1. (See «FRONT UNDER COVER NO.1 REMOVAL/INSTALLATION»(ref-615433-S34343193522014051000000) ).
4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-615406-S03293741932014051000000) ).
5. Remove the following parts: Plug hole plate (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S02010689542014051000000) ). Air cleaner, air hose and fresh air duct component (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615404-S24638618012014051000000) ). Coolant reserve tank (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615406-S37590576392014051000000) ). Cooling fan component (See «COOLING FAN MOTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615406-S32490169072014051000000) ). Radiator (See «RADIATOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615406-S23709300162014051000000) ).
6. Remove the bolts.
7. Disconnect the cooler hose (HI) and cooler pipe. Do not allow remaining compressor oil in the refrigerant line to spill. (See «REFRIGERANT LINE REMOVAL/INSTALLATION»(ref-615407-S04887267312014051000000) ). 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 88): Identifying Cooler Hose (HI) And Cooler Pipe With Mounting Bolts And Torque Specifications
8. Remove the condenser, being careful not to allow remaining compressor oil in the condenser to spill. (See «CONDENSER INSTALLATION NOTE»(ref-615407-S32870267282014051000000) ). 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 89): Identifying Condenser
9. Install in the reverse order of removal.
10. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 2.0]»(ref-615406-S41034731322014051000000) ).
11. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-615479-S38875091672014051000000) ).

Condenser Installation Note

1. After replacing the condenser, add compressor oil to the refrigeration cycle. Supplemental oil amount (approx. quantity) 13 ml {13 cc, 0.44 fl oz}

Receiver/drier Installation Note

1. After replacing the receiver/drier, add compressor oil to the refrigeration cycle. Supplemental oil amount (approx. quantity) 2 ml {2 cc, 0.1 fl oz}

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

1. Remove the battery. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-615406-S03293741932014051000000) ).
3. Remove the insulator. (Scheme 90): Identifying Insulator Mounting Nuts
4. Remove the clips and remove the heater hose. (Scheme 91): Identifying Heater Hose And Clip (Scheme 92): Identifying Heater Hose With Water Temperature Sensor And Clip
5. Remove the heater hose. (Scheme 93): Identifying Heater Hose And Clip (Scheme 94): Removing Heater Hose
6. Install in the reverse order of the removal.
7. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 2.0]»(ref-615406-S41034731322014051000000) ).

Scheme 95

Scheme 96

Scheme 97

1. Remove the battery. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-615406-S03293741932014051000000) ).
3. Remove the insulator. see scheme 38: Identifying Insulator Mounting Nuts (Without Water Temperature Sensor)
4. Remove the clips and remove the heater hose. (Scheme 95): Identifying Heater Hose And Clip (Scheme 96): Identifying Heater Hose And Clip (Scheme 97): Removing Heater Hose
5. Install in the reverse order of the removal.
6. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 2.0]»(ref-615406-S41034731322014051000000) ).

Scheme 98

Scheme 99

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Discharge the refrigerant. (See «REFRIGERANT CHARGING»(ref-615479-S35473472702014051000000) ).
3. Disconnect the engine ground.
4. Disconnect the refrigerant pressure sensor connector.
5. Remove in the order indicated in the table. Do not allow compressor oil to spill. 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. (Scheme 98): Identifying Cooler Hose, Engine Ground, Refrigerant Pressure Sensor Connector Clip And Bolts With Torque Specifications (Scheme 99): Identifying Receiver/Drier Bracket And Bolt With Torque Specifications
6. Install in the reverse order of removal.
7. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-615479-S38875091672014051000000) ).

Refrigerant Line Installation Note (1)

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

Scheme 100

1. Tighten the joint bolt 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 100): Tightening Connection Bolt Or Nut Using Torque Wrench

Refrigerant Line Installation Note (2)

1. After replacing the refrigerant line, add compressor oil to the refrigeration cycle. After replacing the cooler hose (HI) Supplemental oil amount (approx. quantity) 1 ml {1 cc, 0.03 fl oz} After replacing the cooler hose (LO) Supplemental oil amount (approx. quantity) 3 ml {3 cc, 0.1 fl oz} After replacing the cooler pipe Supplemental oil amount (approx. quantity) 1 ml {1 cc, 0.03 fl oz}