Mazda 2: A/C Unit
A/C UNIT REMOVAL/INSTALLATION
1. Set the air intake mode to REC.
2. Disconnect the negative battery cable.
3. Collect the refrigerant. (See REFRIGERANT CHARGING).
4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT).
5. Remove the following parts:
- Glove compartment (See GLOVE COMPARTMENT REMOVAL/INSTALLATION).
- Dashboard under cover (See DASHBOARD UNDER COVER
REMOVAL/INSTALLATION).
- Heat duct (RH) (See HEAT DUCT COMPONENT REMOVAL/INSTALLATION).
- Rear console (See REAR CONSOLE REMOVAL/INSTALLATION).
- Shift lever knob (MTX) (See MANUAL TRANSAXLE SHIFT MECHANISM
REMOVAL/INSTALLATION).
- Side wall (See SIDE WALL REMOVAL/INSTALLATION).
- Front console component (See FRONT CONSOLE COMPONENT
REMOVAL/INSTALLATION).
- Front scuff plate (See FRONT SCUFF PLATE REMOVAL/INSTALLATION).
- Front side trim (See FRONT SIDE TRIM REMOVAL/INSTALLATION).
- Hood release lever (See HOOD LATCH AND RELEASE LEVER
REMOVAL/INSTALLATION).
- Driver's side lower panel (See LOWER PANEL REMOVAL/INSTALLATION).
- Knee bolster (See KNEE BOLSTER REMOVAL/INSTALLATION).
- Driver-side air bag module (See DRIVER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION).
- Steering wheel (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION).
- Column cover (See COLUMN COVER REMOVAL/INSTALLATION).
- Meter hood (See METER HOOD REMOVAL/INSTALLATION).
- Instrument cluster (See INSTRUMENT CLUSTER REMOVAL/INSTALLATION).
- Combination switch (See COMBINATION SWITCH REMOVAL/INSTALLATION).
- Center panel unit (See CENTER PANEL UNIT REMOVAL/INSTALLATION).
- Climate control unit (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION
[MANUAL AIR CONDITIONER] ).
- Shift lever (MTX) (See MANUAL TRANSAXLE SHIFT MECHANISM
REMOVAL/INSTALLATION).
- Selector lever (ATX) (See AUTOMATIC TRANSAXLE SHIFT MECHANISM
REMOVAL/INSTALLATION).
- Interlock unit (ATX) (See AUTOMATIC TRANSAXLE SHIFT MECHANISM
REMOVAL/INSTALLATION).
- Passenger's side lower panel (See LOWER PANEL REMOVAL/INSTALLATION).
- Side panel (See SIDE PANEL REMOVAL/INSTALLATION).
- A-pillar trim (See A-PILLAR TRIM REMOVAL/INSTALLATION).
- Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE
REMOVAL/INSTALLATION).
- Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION).
- Windshield wiper motor (See WINDSHIELD WIPER MOTOR
REMOVAL/INSTALLATION).
- Sail garnish (See SAIL GARNISH REMOVAL/INSTALLATION).
- Steering shaft cover (See STEERING WHEEL AND COLUMN
REMOVAL/INSTALLATION).
- Steering shaft (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION).
6. Disconnect the vehicle wiring harnesses related to the dashboard.
7. Disconnect the antenna feeder No.1 jack.
8. Remove the dashboard. (See DASHBOARD REMOVAL/INSTALLATION).
9. Remove the air cleaner installation bolt and slide the air cleaner component
aside.
10. Disconnect the heater hose from the A/C unit. (See HEATER HOSE
REMOVAL/INSTALLATION).
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.
11. Using the SSTs (49 B061 014, 49 G061 001), disconnect the cooler pipe and
cooler hose
from the A/C unit while preventing the remaining compressor oil in the pipe and
A/C unit
from spilling. (See REFRIGERANT LINE REMOVAL/INSTALLATION).

12. Remove the air intake duct. (See AIR INTAKE DUCT REMOVAL/INSTALLATION).
13. Remove in the order indicated in the table.

- Cap
- A/C unit
14. Install in the reverse order of removal.
15. Perform the refrigerant system performance test. (See REFRIGERANT SYSTEM
PERFORMANCE TEST).
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)
- 27 ml {27 cc, 0.91 fl oz}
A/C UNIT DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the figure.
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.



X Applicable
Heater Core Removal/Installation Note
CAUTION:
- When removing or installing the heater core, hold the heater core side
of the pipe connecting area. Holding the pipe side may
cause a bend on the crimped area of the pipe connecting area, resulting in
heater core damage.

Adhesive Polyurethane (2) Removal Note
CAUTION:
- Because of the possibility of condensation forming, whenever possible
remove the adhesive polyurethane carefully so that it does
not damage the adhesive sponge rubber on the outlet pipe.
Outlet Pipe Removal Note
1. Make a hole in the position shown in the figure for the adhesive
polyurethane (2) and install the outlet pipe installation bolt.

Tightening Torque
- 6.8-9.8 N*m {70-99 kgf*cm, 61-86 in*lbf}
2. Tear off the adhesive polyurethane (2) from the joint area of the
expansion valve and outlet pipe.
3. Remove the outlet pipe from the expansion valve.
A/C Case Disassembly Note
1. Cut the adhesive polyurethane (4) along the contacting surfaces of the
case.

Evaporator Temperature Sensor Assembly Note
1. Assemble the evaporator temperature sensor as shown in the figure.

CAUTION:
- When installing the evaporator temperature sensor without newly
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:
- Newly replace an evaporator in which the evaporator temperature sensor
cannot be correctly positioned.
Adhesive Polyurethane (2) Installation Note
1. Align the adhesive polyurethane (2) notch with the center of the lower
surface of the expansion valve, and adhere.

2. Roll on the adhesive polyurethane (2) so that it wraps around the
expansion valve.

3. Bend around the adhesive polyurethane (2) and adhere it to the outlet
pipe.

READ NEXT:
AIR INTAKE DUCT REMOVAL/INSTALLATION
1. Set the air intake mode to REC.
2. Disconnect the negative battery cable.
3. Remove the following parts:
Glove compartment (See GLOVE COMPARTMENT REMOVAL/IN
AIR FILTER REMOVAL/INSTALLATION
CAUTION:
When installing the air filter cover, verify that the seals on the back
of the cover are assembled securely. If the
air filter cover is installed with the
AIRFLOW MODE LINK SET REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the following parts:
Rear console (See REAR CONSOLE REMOVAL/INSTALLATION).
Shift lever knob (MTX) (Se
SEE MORE:
If the buttons on the transmitter are
inoperable and the operation indicator
light does not fl ash, the battery may be
dead.
Replace with a new battery before the
transmitter becomes unusable.
CAUTION
Make sure the battery is installed
correctly. Battery leakage could
occur if it is not i
CLUTCH LOCATION INDEX
Reserve tank
(See CLUTCH FLUID INSPECTION)
(See CLUTCH FLUID AIR BLEEDING/REPLACEMENT)
Clutch master cylinder
(See CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION)
Clutch pedal
(See CLUTCH PEDAL INSPECTION)
(See CLUTCH PEDAL REMOVAL/INSTALLATION)
Clutch
© 2016-2023 Copyright www.ma2auto.com
