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

AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.
2. Remove the glove compartment. (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-343786-S18889764722009101500000) ).
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

BLOWER MOTOR REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.
2. Remove the dashboard under cover (passenger's side).
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

Scheme 18

1. Connect battery positive voltage to terminal B and ground to terminal A of the blower motor and verify its operation. If not as specified, replace the blower motor.

Scheme 19

1. Disconnect the negative battery cable.
2. Remove the glove compartment. (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-343786-S18889764722009101500000) ).
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

Scheme 20

1. Verify that the resistance between the terminals of the power MOS FET is as shown in the table. If there is any malfunction, replace the power MOS FET. TESTER LEAD RESISTANCE CHART Tester lead Resistance (kilohm) + - A B infinity A E 6.9 B A Continuity B E Continuity E A 6.9 E B infinity

Scheme 21

1. Disconnect the negative battery cable.
2. Remove the glove compartment. (See «RESISTOR REMOVAL/INSTALLATION»(ref-343768-S20172986282009101500000) .)
3. Remove in the order indicated in the figure.
4. Install in the reverse order of removal.

Scheme 22

1. Verify that the resistance between the terminals of the resistor is as shown in the table. If not as specified, replace the resistor. TERMINAL RESISTANCE SPECIFICATION Terminal Resistance (ohm) A-D 0.29 A-B 0.99 A-C 2.76

Scheme 23

1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
3. Adjust the magnetic clutch clearance. (See «MAGNETIC CLUTCH ADJUSTMENT»(ref-343768-S37651000802009101500000) .)

Scheme 24

Scheme 25

1. When removing or installing the bolt, lock the A/C compressor pulley against rotation using the following procedure: CAUTION: When connecting the positive battery cable to the magnetic clutch connector, use a cable with a female terminal of the correct size. Otherwise, load will be applied to the terminal resulting in deformation or damage and poor contact. In addition, the positive battery cable could disconnect from the connector resulting in a short circuit. Apply battery positive voltage to the magnetic clutch terminal and connect the A/C compressor body to the ground. Wrap the drive belt, which is no longer of use, tightly around the A/C compressor pulley. Hold the drive belt in place with pliers. Remove/Install the bolt.

Tightening torque

15 N.m (1.5 kfg.m, 11 ft.lbf)

Scheme 26

A/C Compressor Pulley Removal Note

1. Remove the A/C compressor pulley using the SSTs (49 0839 425C, 49 SE01 160). CAUTION: Be careful that the SST (49 0839 425C) tabs do not hang over the stator.

Scheme 27

Note. Taping on the nail to protect from damage.

Scheme 28

A/C Compressor Pulley Installation Note

1. Install the inner wheel of the pulley using SST (49 D034 202) to the compressor. CAUTION: If the SST is not properly positioned when the A/C compressor pulley is press-fit, the A/C compressor axle will interfere with the SST, possibly damaging component parts. Verify the SST and axle are properly positioned and perform the procedure very carefully.

Scheme 29

Snap Ring Removal/Installation Note

1. Remove/Install the snap ring using a snap ring pliers.

Scheme 30

Shim Installation Note

1. First, insert the 1mm (0.039 in) thick shim into the shaft.

Scheme 31

Scheme 32

Scheme 33

1. Measure the clearance around the entire circumference between the pressure plate and A/ C compressor pulley using a thickness gauge.
2. Verify that the clearance is within the specification. If not within the specification, remove the pressure plate and adjust the clearance by changing the shim (0.2 mm {0.008 in}, 0.5 mm {0.02 in}) or the number of shims. Magnetic clutch clearance 0.35-0.65 mm {0.014-0.025 in}

Scheme 34

1. Connect battery positive voltage 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 stator and thermal protector.

Scheme 35

1. Disconnect the negative battery cable.
2. Remove the dashboard under cover (driver's side).
3. Press out the solar radiation sensor with its connector from under the instrument panel.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.

Scheme 36

Scheme 37

1. Shine a fluorescent light or expose the solar radiation sensor to natural sunlight.
2. Connect the positive (+) lead to terminal A and the negative (-) lead to terminal B of the solar radiation sensor, and verify that the voltages are as shown in the table. If the voltage is not as specified, replace the solar radiation sensor.

Scheme 38

1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

PASSENGER COMPARTMENT TEMPERATURE SENSOR REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.
2. Remove the following parts: Front scuff plate inner (driver's side). (See «FRONT SCUFF PLATE REMOVAL/INSTALLATION»(ref-343786-S38441409102009101500000) ). Front side trim (driver's side). (See «FRONT SIDE TRIM REMOVAL/INSTALLATION»(ref-343786-S15930681492009101500000) ). Console panel. (See «CONSOLE PANEL REMOVAL/INSTALLATION»(ref-343786-S08749156142009101500000) ). Console. (See «CONSOLE REMOVAL/INSTALLATION»(ref-343786-S27142773812009101500000) ). Hood release lever. (See «HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION»(ref-343765-S32881423572009101500000) ). Lower panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-343786-S13450056682009101500000) ).
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

Scheme 39

1. Measure the temperature around the passenger compartment temperature sensor.
2. Measure the resistance between terminals of the passenger compartment temperature sensor. If the resistance is not as shown in the graph, replace the passenger compartment temperature sensor.

EVAPORATOR TEMPERATURE SENSOR REMOVAL/INSTALLATION

1. Remove the evaporator temperature sensor from the A/C unit. (See «A/C UNIT DISASSEMBLY/ASSEMBLY»(ref-343797-S12338181722009101500000) ).

Scheme 40

1. Set the fan speed MAX HI.
2. Set the temperature control at MAX COLD (Turn to 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-343786-S18889764722009101500000) ).
8. Disconnect the evaporator temperature sensor connector.
9. Measure the temperature at the blower inlet.
10. Measure the resistance between terminals of the evaporator temperature sensor. If the resistance is not as shown in the graph, replace the evaporator temperature sensor.

REFRIGERANT PRESSURE SWITCH REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See «REFRIGERANT RECOVERY»(ref-343798-S38038311702009101500000) .) (See «REFRIGERANT CHARGING»(ref-343798-S00570161812009101500000) ).
3. Loosen the refrigerant pressure switch using two spanners.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-343798-S08047576452009101500000) ).

Refrigerant Pressure Switch Installation Note

1. Apply compressor oil to O-ring and connect the joint.

Scheme 41

Scheme 42

Scheme 43

1. Install the manifold gauge.
2. Disconnect the refrigerant pressure switch connector.
3. Verify the high-pressure side reading of the manifold gauge and continuity between the terminals of the refrigerant pressure switch. If the continuity is not normal, replace the refrigerant pressure switch.

Scheme 44

1. Disconnect the negative battery cable.
2. Remove the following parts: Console (See «CONSOLE REMOVAL/INSTALLATION»(ref-343786-S27142773812009101500000) ). Lower panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-343786-S13450056682009101500000) ). Center panel (See «CENTER PANEL REMOVAL/INSTALLATION»(ref-343786-S24939434152009101500000) ). Audio unit (See «AUDIO UNIT REMOVAL/INSTALLATION»(ref-343789-S01824972822009101500000) ).
3. Remove the screws and climate control unit.
4. Release the tab and pull the climate control unit toward you.
5. Disconnect the climate control unit connectors and remove the climate control unit.
6. Install in the reverse order of removal.

Scheme 45

Scheme 46

1. Disconnect the negative battery cable.
2. Remove the following parts: Glove compartment. (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-343786-S18889764722009101500000) ). Console (See «CONSOLE REMOVAL/INSTALLATION»(ref-343786-S27142773812009101500000) ). Lower panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-343786-S13450056682009101500000) ). Center panel (See «CENTER PANEL REMOVAL/INSTALLATION»(ref-343786-S24939434152009101500000) ). Audio unit (See «AUDIO UNIT REMOVAL/INSTALLATION»(ref-343789-S01824972822009101500000) ).
3. Disconnect the air mix wire from wire clamp and link.
4. Remove the screws and climate control unit.
5. Release the tab and pull the climate control unit toward you.
6. Disconnect the climate control unit connectors and remove the climate control unit.

Scheme 47

1. Pass air mix wire through the following routes then connect to A/C unit. (Manual air conditioner)
2. Install the following parts: Climate control unit to the dashboard. Audio unit (See «AUDIO UNIT REMOVAL/INSTALLATION»(ref-343789-S01824972822009101500000) ). Center panel (See «CENTER PANEL REMOVAL/INSTALLATION»(ref-343786-S24939434152009101500000) ). Lower panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-343786-S13450056682009101500000) ). Console (See «CONSOLE REMOVAL/INSTALLATION»(ref-343786-S27142773812009101500000) ).
3. Adjust the air mix wire. (See «CLIMATE CONTROL UNIT WIRE ADJUSTMENT»(ref-343768-S11080765982009101500000) .)
4. Install the globe compartment.