HVAC System: Other Mazda RX-8 I

FOREWORD

1. The areas for inspection (steps) are given according to various circuit malfunctions. Use the following chart to verify the symptoms of the trouble in order to diagnose the appropriate area.

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TROUBLESHOOTING CODES

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1. When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while performing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and undamaged.

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Scheme 76

1. When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while performing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and undamaged.

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Scheme 80

1. When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If there is a problem, check to make sure connectors, terminals and wiring harness are connected correctly and undamaged.

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Scheme 87

1. When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while performing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and undamaged.

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Using/Handling Unapproved Refrigerant

1. Using a flammable refrigerant, such as OZ-12, in this vehicle is dangerous. In an accident, the refrigerant may catch fire, resulting in serious injury or death. When servicing this vehicle, use only R-134a.
2. Checking for system leakage on a vehicle that has been serviced with flammable refrigerant, such as OZ-12, is dangerous. Conventional leak detectors use an electronically generated arc which can ignite the refrigerant, causing serious injury or death. If a flammable refrigerant may have been used to service the system, or if you suspect a flammable refrigerant has been used, contact the local fire marshal or EPA office for information on handling the refrigerant.

Handling Refrigerant

1. Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose and throat. Also, due to environmental concerns, use service equipment certified to meet the requirements of SAE J2210 (R-134a recycling equipment) when draining R-134a from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service.
2. Do not pressure test or leak test R-134a service equipment and/or vehicle air conditioning system with compressed air. Some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers.
3. Do not allow the refrigerant to leak near fire or any kind of heat. A poisonous gas may be generated if the refrigerant gas contacts fire or heat such as from cigarettes and heaters. When carrying out any operation that can cause refrigerant leakage, extinguish or remove the above-mentioned heat sources and maintain adequate ventilation.
4. Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostbite. When handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes, immediately wash them with clean water and consult a doctor.

Storing Refrigerant

1. The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Store the refrigerant at temperatures below 40°C {104°F}.

Scheme 92

1. Use only DENSO OIL8 compressor oil for this vehicle. Using PAG oil other than DENSO OIL8 compressor oil can damage the A/C compressor.
2. Do not spill DENSO OIL8 compressor oil on the vehicle. A drop of compressor oil on the vehicle surface can eat away at the paint. If oil gets on the vehicle, wipe it off immediately.
3. DENSO OIL8 compressor oil (PAG oil) has a higher moisture absorption efficiency than the previously used mineral oil. If moisture mixes with the compressor oil, the refrigerant system could be damaged. Therefore, install caps immediately after using the compressor oil or removing refrigerant system parts to prevent moisture absorption.

Scheme 93

1. Fully close the valves of the manifold gauge.
2. Connect the charging hoses to the high/low pressure side joints of the manifold gauge.
3. Connect the quick couplers to the ends of the charging hoses.
4. Connect the quick couplers to the charging valves.

REFRIGERANT RECOVERY

REFRIGERANT CHARGING

Charging Recycled R-134a Refrigerant

1. Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer's instructions.

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1. Install the manifold gauge set.
2. Connect the tap pin side of the charging hose to the air purge valve of the manifold gauge.
3. Connect the vacuum pump hose to the center joint of the manifold gauge.
4. Connect the vacuum pump hose to the vacuum pump.
5. Connect the charging hose to the refrigerant tank.
6. Place the refrigerant tank on the scale.
7. Open all the valves of the manifold gauge. CAUTION: Close the manifold gauge valve immediately after stopping the vacuum pump. If the valve is left open, the vacuum pump oil will back flow into the refrigeration cycle and cause a decrease in the efficiency of the air conditioner.
8. Start the vacuum pump and let it operate for 15 min.
9. Verify that high-and low-pressure side readings of the manifold gauge are at -101 kPa {-760 mmHg, -29.9 inHg}. Close each valve of the manifold gauge.
10. Stop the vacuum pump and wait for 5 min.
11. Inspect the high-and low-pressure side readings of the manifold gauge. If the reading has changed, inspect for leakage and then repeat from Step 7 . If the reading has not changed, go to next step.
12. Open the valve of the refrigerant tank.
13. Weigh the refrigerant tank to charge the suitable amount of refrigerant. Regular amount of refrigerant (approx. quantity) 430 g {15.2 oz} WARNING: If the refrigerant system is charged with a large amount of refrigerant when checking for gas leakage, and if any leakage should occur, the refrigerant will be released into the atmosphere. In order to prevent the accidental release of refrigerant which can destroy the ozone layer in the stratosphere, follow the proper procedures and charge with only a small amount of refrigerant when checking for gas leakage. If charging the system with refrigerant by service cans or refrigerant tank, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans or refrigerant tank will increase and they could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.
14. Open the low-pressure side valve of the manifold gauge.
15. When the high-pressure side reading increases to 98 kPa {1.0 kgf/cm 2 , 14 psi}, close the low-pressure side valve of the manifold gauge.
16. Inspect for leakage from the cooler pipe/hose connections using a gas leak tester. If there is no leakage, go to Step 18 . If leakage is found at a loose joint, tighten the joint, go to next step.
17. Inspect for leakage again. If there is no leakage after tightening the joint, go to next step. If there is still a leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from Step 7 . WARNING: If charging the system with refrigerant by service cans or refrigerant tank, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans or refrigerant tank will increase and they could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.
18. Open the low-pressure side valve of the manifold gauge and charge with refrigerant until the weight of refrigerant tank has decreased 200 g {7.06 oz} from the amount in Step 13.
19. Close the low-pressure side valve of the manifold gauge. WARNING: If charging the system with refrigerant by service cans or refrigerant tank, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans or refrigerant tank will increase and they could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.
20. Start the engine and actuate the A/C compressor.
21. Open the low-pressure side valve of the manifold gauge and charge with refrigerant until the weight of the refrigerant tank has decreased 430 g {15.2 oz} from the amount in Step 13.
22. Close the low-pressure side valve of the manifold gauge and the valve of the refrigerant tank.
23. Stop the engine and A/C compressor.
24. Inspect for leakage using a gas leak tester. If there is no leakage, go to Step 26 . If leakage is found at a loose joint, tighten the joint, then go to next step.
25. Inspect for leakage again. If there is still leakage after tightening the joint, go to next step. If there is still leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from Step 7 .
26. Remove the manifold gauge set.
27. Install the caps to the charging valves.

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1. Disconnect the negative battery cable.
2. Remove the following parts: Ashtray Console (See «CONSOLE REMOVAL/INSTALLATION»(ref-178403-S38824949812005061500000) .) Glove compartment (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-178403-S18416452892005061500000) ). Side panel (See «SIDE PANEL REMOVAL/INSTALLATION»(ref-178403-S13157293282005061500000) .) Lower panel (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-178403-S02200989262005061500000) .) Column cover (See «COLUMN COVER REMOVAL/INSTALLATION»(ref-178403-S19828048582005061500000) .) Steering shaft installation nuts (See «STEERING WHEEL & COLUMN REMOVAL/INSTALLATION»(ref-178305-S33200224622005061400000) .) A-pillar trim (See «A-PILLAR TRIM REMOVAL/INSTALLATION»(ref-178403-S21109983142005061500000) .) Dashboard (See «DASHBOARD REMOVAL/INSTALLATION»(ref-178403-S29776327272005061500000) .)
3. Remove the A/C unit from the dashboard.
4. Remove the blower unit as shown in the figure.
5. Install in the reverse order of removal.

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1. Disassemble in the order indicated in (Scheme 105). 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.

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1. Remove the glove compartment. See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-178403-S18416452892005061500000).
2. Remove in the order indicated in (Scheme 107).
3. Install in the reverse order of removal.