Basic System (HVAC): Removal & Installation Mazda CX-7 I

A/C Unit Installation Note

1. When installing a new A/C unit or evaporator, add a supplemental amount of ATMOS GU10 compressor oil into the refrigerant cycle. Supplemental amount (approx. quantity) 25 ml {25 cc, 0.8 fl oz}

Scheme 34

Scheme 35

1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

Scheme 36

1. Attach the sensor clamp as shown in the figure.

Scheme 37

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

Scheme 38

Scheme 39

1. Attach the adhesive polyurethane (2) as shown in the figure.
2. After assembling the evaporator pipe as shown in the figure, attach the adhesive polyurethane (2) so that it adheres around the high-pressure side of the evaporator pipe.

Scheme 40

1. Attach the adhesive polyurethane (4) so that it adheres around the expansion valve.

Scheme 41

1. Attach the adhesive polyurethane (3) so that it adheres around the low-pressure side of the evaporator pipe.

Scheme 42

1. Attach the adhesive polyurethane (1) as shown in the figure.

Scheme 43

1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See «REFRIGERANT RECOVERY»(ref-269017-S00065438922007102700000) .) (See «REFRIGERANT CHARGING»(ref-269017-S34224364942007102700000) ). CAUTION: If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.
3. Remove the insulator. (See «A/C UNIT REMOVAL/INSTALLATION»(ref-269018-S12943361312007102700000) .)
4. Disconnect the cooler hose (LO) and cooler pipe. (See «A/C UNIT REMOVAL/INSTALLATION»(ref-269018-S12943361312007102700000) .)
5. Remove the following parts: Dashboard under cover Front scuff plate inner (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-269050-S34251263902007102700000) ). Front side trim (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-269050-S13516748582007102700000) ). Console panel (See «CONSOLE PANEL REMOVAL/INSTALLATION»(ref-269050-S29358925182007102700000) ). Console (See «CONSOLE REMOVAL/INSTALLATION»(ref-269050-S01041673842007102700000) ). Glove compartment (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-269050-S11046456102007102700000) ). Hood release (See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-269047-S41720534972007102700000) ). Lower panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-269050-S05344216152007102700000) ). Center panel (See «CENTER PANEL REMOVAL/INSTALLATION»(ref-269050-S19487269542007102700000) ). Passenger-side air bag module (See «SIDE AIR BAG MODULE REMOVAL/INSTALLATION»(ref-269024-S41362178802007102700000) ).
6. Remove the airflow mode actuator. (See «AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION»(ref-269019-S08853257682007102700000) ).
7. Disconnect the air intake actuator connector.
8. Remove the duct (1).
9. Remove the adhesive polyurethane (1). (See «A/C UNIT DISASSEMBLY/ASSEMBLY»(ref-269018-S30148931032007102700000) .) CAUTION: Being careful not to damage the adhesive sponge rubber or adhesive polyurethane, remove adhesive polyurethane completely.
10. Remove the one bolt and shift the evaporator pipe. Do not allow compressor oil to spill.
11. Remove the two bolts.
12. Remove the expansion valve. Do not allow compressor oil to spill.
13. Remove the screws and plate.
14. Remove the adhesive polyurethane (2). (See «A/C UNIT DISASSEMBLY/ASSEMBLY»(ref-269018-S30148931032007102700000) .) CAUTION: Being careful not to damage the adhesive sponge rubber or adhesive polyurethane, remove adhesive polyurethane completely.
15. Remove the adhesive polyurethane (3). (See «A/C UNIT DISASSEMBLY/ASSEMBLY»(ref-269018-S30148931032007102700000) .) CAUTION: Being careful not to damage the adhesive sponge rubber or adhesive polyurethane, remove adhesive polyurethane completely.
16. Remove the adhesive polyurethane (4). (See «A/C UNIT DISASSEMBLY/ASSEMBLY»(ref-269018-S30148931032007102700000) .)
17. Install in the reverse order of removal.
18. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-269017-S19050498962007102700000) ).

Scheme 44

Scheme 45

Scheme 46

1. Disconnect the negative battery cable.
2. Remove the following parts: Console panel (See «CONSOLE PANEL REMOVAL/INSTALLATION»(ref-269050-S29358925182007102700000) ). Console (See «CONSOLE REMOVAL/INSTALLATION»(ref-269050-S01041673842007102700000) ). Front scuff plate inner (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-269050-S34251263902007102700000) ). Front side trim (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-269050-S13516748582007102700000) ). Dashboard under cover Glove compartment (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-269050-S11046456102007102700000) ). Hood release lever (See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-269047-S41720534972007102700000) ). Lower panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-269050-S05344216152007102700000) ). Center panel (See «CENTER PANEL REMOVAL/INSTALLATION»(ref-269050-S19487269542007102700000) ). Audio unit (See «AUDIO UNIT REMOVAL/INSTALLATION»(ref-269053-S11995302372007102700000) ). Climate control unit (See «CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER]»(ref-269019-S13274020272007102700000) or «CLIMATE CONTROL UNIT REMOVAL [MANUAL AIR CONDITIONER]»(ref-269019-S13292264222007102700000) ). Knee bolster (See «KNEE BOLSTER REMOVAL/INSTALLATION»(ref-269050-S20061919862007102700000) ). Meter hood (See «METER HOOD REMOVAL/INSTALLATION»(ref-269050-S37165522602007102700000) ). Column cover (See «COLUMN COVER REMOVAL/INSTALLATION»(ref-269050-S25734514712007102700000) ). Instrument cluster (See «INSTRUMENT CLUSTER REMOVAL/INSTALLATION»(ref-269055-S06211693682007102700000) ). Driver-side air bag module (See «DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION»(ref-269024-S06836863402007102700000) ). Steering wheel (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION»(ref-269012-S00459439552007102700000) ). Combination switch (See «COMBINATION SWITCH REMOVAL/INSTALLATION»(ref-269051-S39570818122007102700000) ). Steering shaft (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION»(ref-269012-S00459439552007102700000) ). A-pillar lower trim (See «A-PILLAR LOWER TRIM REMOVAL/INSTALLATION»(ref-269050-S26657353762007102700000) ). A-pillar trim (See «A-PILLAR TRIM REMOVAL/INSTALLATION»(ref-269050-S28084858322007102700000) ). Dashboard (See «DASHBOARD REMOVAL/INSTALLATION»(ref-269050-S21272771312007102700000) ).
3. Remove the blower motor. (See «BLOWER MOTOR REMOVAL/INSTALLATION»(ref-269019-S41961936212007102700000) ).
4. Remove the power MOS FET (Full-auto air conditioner) or resistor. (Manual air conditioner) (See «POWER METAL OXIDE SEMICONDUCTOR FIELD EFFECT TRANSISTOR (POWER MOS FET) REMOVAL/INSTALLATION»(ref-269019-S01200935752007102700000) .) (See «RESISTOR REMOVAL/INSTALLATION»(ref-269019-S42143967682007102700000) ).
5. Remove the blower unit installation nuts.
6. Remove the screw securing the duct (2) to the A/C unit, by inserting a phillips screwdriver into the hole made after removing the blower motor.
7. Remove the screw securing the duct (2) to the A/C unit.
8. Remove the duct (2).
9. Remove the blower unit.
10. Temporary install the blower unit.
11. Install in the duct (2).
12. Install the two outer screws, securing the duct (2) to the A/C unit.
13. Install the screw on the end of the phillips screwdriver with the packing tape. CAUTION: If the packing tape remains in the duct (2), it may become a source of noise. Wind up the packing tape to prevent pinching when tightening the screw.
14. Install the duct (2) to the A/C unit by inserting a phillips screwdriver, with the screw, into the hole made after removing the blower motor.
15. Pull out the phillips screwdriver together with the packing tape.
16. Install in the reverse order of removal.

Scheme 47

1. Disassemble in the order indicated in the table. CAUTION: Apply only the specified grease to the link. Otherwise abnormal noise or improper operation may result.
2. Assemble in the reverse order of disassembly.

AIR FILTER REMOVAL/INSTALLATION

Scheme 48

1. Remove the glove compartment. (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-269050-S11046456102007102700000) ).
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

A/C Compressor Installation Note

Scheme 49

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 A/C 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 ATMOS GU10 A/C compressor oil sealed volume (approx. quantity) 120ml{120cc, 4.06floz}

Scheme 50

1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See «REFRIGERANT RECOVERY»(ref-269017-S00065438922007102700000) .) (See «REFRIGERANT CHARGING»(ref-269017-S34224364942007102700000) ).
3. Disconnect the body earth cable installed to NO. 3 engine mount rubber.
4. Disconnect the insulator. (See «A/C UNIT REMOVAL/INSTALLATION»(ref-269018-S12943361312007102700000) .)
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.
6. Install in the reverse order of removal.
7. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-269017-S19050498962007102700000) ).

Scheme 51

Scheme 52

Scheme 53

1. Set the SST.
2. While looking through the inspection hole of the SST , insert the protruding part of the SST until it makes contact with the cage section.
3. Use the SST to disconnect the male pipe or hose from the female by pulling the male pipe or hose. NOTE: The male pipe or hose can be disconnected easily from the female pipe by pulling from the male pipe or hose while maintaining the pressure of the protruding part of the SST.

Refrigerant Line Installation Note

1. When installing a new cooler pipe or cooler hose, add a supplemental amount of ATMOS GU10 compressor oil into the refrigeration cycle. Supplemental amount (approx. quantity) 5 ml {5 cc, 0.2 fl oz}: Cooler pipe 10 ml {10 cc, 0.3 fl oz}: Cooler hose
2. Apply compressor oil to the O-rings and connect the joints.
3. Tighten the joints.

Scheme 54

1. Connect the male pipe or hose by pushing it while slightly twisting it onto female pipe until the garter spring at the male pipe or hose is over the flared end of female pipe. NOTE: When the male pipe or hose is replaced, the indicator ring comes out after connecting to indicate that it is locked.

Scheme 55

1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See «REFRIGERANT RECOVERY»(ref-269017-S00065438922007102700000) .) (See «REFRIGERANT CHARGING»(ref-269017-S34224364942007102700000) ).
3. Remove the air cleaner. (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268965-S28635226732007102700000) ).
4. Remove the splash shield.
5. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT[L3 WITH TC]»(ref-268964-S25805555392007102700000) ).
6. Remove the following parts: Charge air cooler duct, air cleaner and fresh air duct component (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268965-S28635226732007102700000) ). Coolant reserve tank (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268964-S10390752252007102700000) ). Dipstick pipe (See «OIL PAN REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268963-S23117871082007102700000) ). Cooling fan component (See «FAN MOTOR REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268964-S32785521252007102700000) ).
7. Remove the radiator. (See «RADIATOR REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268964-S10616545622007102700000) ). 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.
8. Remove in the order indicated in the table. Do not allow compressor oil to spill.
9. Install in the reverse order of removal.
10. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-269017-S19050498962007102700000) ).

Condenser Installation Note

1. After replacing the condenser, add compressor oil to the refrigeration cycle. Supplemental oil amount (approx. quantity) 20 ml {20 cc, 0.7 fl oz}