HVAC System: Removal & Installation Mazda RX-8 I

A/C Unit Installation Note

1. When installing a new A/C unit or evaporator, add compressor oil to the refrigerant cycle.

Supplemental amount (approx. quantity)

20 ml {20 cc, 0.7 fl oz}

Scheme 24

1. Disassemble in the order indicated in (Scheme 24). 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.

A/C Compressor Installation Note

1. When replacing the A/C compressor, remove the following amount of compressor oil from the new A/C compressor.

Amount drained (approx. quantity)

60 ml {60 cc, 2.03 fl oz} - (Oil amount drained from removed old A/C compressor + 15 ml {15 cc, 0.5 fl oz})

Scheme 25

Scheme 26

1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See «REFRIGERANT CHARGING»(ref-178308-S32782399292005061400000).)
3. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-178321-S36202521982005061400000).)
4. Remove the under cover.
5. Do not allow remaining compressor oil in the condenser and pipes to spill, and remove in the order indicated in (Scheme 25). 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.
6. Install in the reverse order of removal.
7. Perform the refrigerant system performance test. (See «REFRIGERANT SYSTEM PERFORMANCE TEST»(ref-178308-S09431512962005061400000).)

Condenser Installation Note

1. When replacing the new condenser, add compressor oil to the refrigeration cycle.

Supplemental amount (approx. quantity)

20 ml {20cc, 0.7 fl oz}

Refrigerant Line Installation Note

1. Apply compressor oil to the O-ring joints.
2. Tighten the piping joints.

Scheme 27

1. Temporarily 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, and then tighten the connection bolt or nut with a torque wrench.

Scheme 28

Scheme 29

Scheme 30

1. Disconnect the negative battery cable.
2. Remove the glove compartment. (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-178403-S18416452892005061500000) ).
3. Remove the keyless control module. (See «KEYLESS CONTROL MODULE REMOVAL/INSTALLATION»(ref-178400-S08667966882005061500000).)
4. Remove in the order indicated in (Scheme 29).
5. Install in the reverse order of removal.

Scheme 31

Scheme 32

1. Connect battery positive voltage to air intake actuator terminal A (or C), and ground to terminal C (or A), and then verify that the air intake actuator operates (Scheme 31) If the operation condition is not normal, replace the air intake actuator.

Scheme 33

Scheme 34

1. Disconnect the negative battery cable.
2. Remove the A/C amplifier.
3. Remove in the order indicated in (Scheme 33).
4. Install in the reverse order of removal.

Scheme 35

Scheme 36

Scheme 37

1. Connect battery positive voltage to air mix actuator terminal F (or G), and ground to terminal G (or F), and then verify that the air mix actuator operates (Scheme 35) If the operation condition is not normal, replace the air mix actuator.
2. Verify that the resistance between terminals A and E, and C and E matches the air mix actuator operation as shown in the graph. If the operation condition and resistance are not normal, replace the air mix actuator.

Scheme 38

Scheme 39

1. Disconnect the negative battery cable.
2. Remove in the order indicated in (Scheme 38).
3. Install in the reverse order of removal.

Scheme 40

Scheme 41

Scheme 42

1. Connect battery positive voltage to airflow mode actuator terminal F (or G), and ground to terminal G (or F), and then verify that the airflow mode actuator operates (Scheme 40) If the operation condition is not normal, replace the airflow mode actuator.
2. Verify that the resistance between terminals A and E, and C and E matches the airflow mode actuator operation as shown in the graph. If the operation condition and resistance are not normal, replace the airflow mode actuator.

Scheme 43

Scheme 44

1. Disconnect the negative battery cable.
2. Remove in the order indicated in (Scheme 43).
3. Install in the reverse order of removal.

Scheme 45

1. Connect battery positive voltage to blower motor terminal A, ground to terminal B, and then verify that the blower motor operates smoothly. If the operation condition is not normal, replace the blower motor.

Scheme 46

Scheme 47

1. Disconnect the negative battery cable.
2. Remove the glove compartment. (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-178403-S18416452892005061500000).)
3. Remove in the order indicated in (Scheme 46).
4. Install in the reverse order of removal.

Scheme 48

Scheme 49

1. Verify that the resistance between the resistor terminals is as indicated in (Scheme 48). If there is any malfunction, replace the resistor.

Scheme 50

1. Measure the clearance around the entire circumference between the pressure plate and A/C compressor pulley using a feeler gauge.
2. Inspect the clearance. If not within the specification, adjust the clearance by changing the shim (0.2 mm {0.008 in}, 0.5 mm {0.02 in}) or the number of shims.

Standard clearance

0.20-0.45 mm {0.008-0.017 in}

Scheme 51

Scheme 52

1. Connect battery positive voltage to magnetic clutch terminal B and ground to terminal A.
2. Verify that the magnetic clutch turns on. If the magnetic clutch does not turn on, replace the A/C compressor.

Scheme 53

Scheme 54

1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Remove in the order indicated in (Scheme 53).
4. Install in the reverse order of removal.

Scheme 55

1. Measure the temperature around the ambient temperature sensor, then measure the resistance between the terminals of the ambient temperature sensor. If the characteristics of the ambient temperature sensor are not as shown in the graph, replace the ambient temperature sensor.

Scheme 56

Scheme 57

1. Disconnect the negative battery cable.
2. Remove the glove compartment. (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-178403-S18416452892005061500000).)
3. Remove the keyless control module. (See «KEYLESS CONTROL MODULE REMOVAL/INSTALLATION»(ref-178400-S08667966882005061500000).)
4. Remove in the order indicated in (Scheme 56).
5. Install in the reverse order of removal.

Refrigerant Pressure Switch Installation Note

1. Apply compressor oil to the O-ring joints.

Scheme 58

Scheme 59

Scheme 60

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

CLIMATE CONTROL UNIT REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.
2. Remove the lower panel. (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-178403-S02200989262005061500000) .)
3. Remove the console. (See «CONSOLE REMOVAL/INSTALLATION»(ref-178403-S38824949812005061500000) .)
4. Remove the center panel module. (See «CENTER PANEL MODULE REMOVAL/INSTALLATION»(ref-178419-S17768820382005061500000) .)
5. Remove the climate control unit from the center panel module.
6. Install in the reverse order of removal.

Scheme 61

On-Board Diagnostic Test Procedure

1. Disconnect the negative battery cable.
2. Remove the A/C amplifier.
3. Disconnect the A/C amplifier connector (24-pin).
4. Using a jumper wire or a similar device, short circuit A/C amplifier connector (24-pin) terminals 1P and 1R.
5. Connect the negative battery cable.
6. Turn the ignition switch to the ON position (engine off).

Scheme 62

Scheme 63

1. After performing the on-board diagnostic test procedure, inspect according to the table in (Scheme 64).
2. Disconnect the jumper wire or the similar device connected to the A/C amplifier connector (24-pin) to exit the on-board diagnostic test function.

Scheme 64

1. After performing the on-board diagnostic test procedure, turn on the audio.
2. Inspect according to the following table in (Scheme 65).
3. Disconnect the jumper wire or the similar device connected to the A/C amplifier connector (24-pin) to exit the on-board diagnostic test function.

Scheme 65

1. After performing the on-board diagnostic test procedure, turn on the audio.
2. Press the audio POWER and SCAN (upper) buttons simultaneously.
3. "A/C TEMP-" is displayed on the information display.
4. Inspect according to the following table in (Scheme 66).
5. Disconnect the jumper wire or the similar device connected to the A/C amplifier connector (24-pin) to exit the on-board diagnostic test function.

Scheme 66

Scheme 67

1. Inspect for continuity between the fan switch terminals using a tester. If there is any malfunction, replace the fan switch.