Mazda 2: Air Intake Duct
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/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).
- Lower panel (driver-side) (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 component (MTX) (See MANUAL TRANSAXLE SHIFT MECHANISM
REMOVAL/INSTALLATION).
- Selector lever component (ATX) (See AUTOMATIC TRANSAXLE SHIFT
MECHANISM REMOVAL/INSTALLATION
- Interlock unit (ATX) (See AUTOMATIC TRANSAXLE SHIFT MECHANISM
REMOVAL/INSTALLATION).
- Lower panel (passenger-side) (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).
4. Disconnect the dashboard wiring harness connector.
5. Disconnect the antenna feeder No.1 jack.
6. Remove the dashboard. (See DASHBOARD REMOVAL/INSTALLATION).
7. Remove the air intake duct installation bolt.

8. Remove the air intake duct.
9. Install in the reverse order of removal.
AIR INTAKE DUCT DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
CAUTION:
- Apply only the specified grease to links. Otherwise abnormal noise or
improper operation may result.
2. Assemble in the reverse order of disassembly.

- Wire clamp
- Air intake link set
- Air intake duct case (1)
- Air intake duct case (2)
- Air intake door
- Adhesive polyurethane
Air Intake Duct Case Disassembly Note
1. Align the contacting surfaces of air intake duct case (1) and (2), and cut
the adhesive polyurethane.

EXPANSION VALVE REMOVAL
1. Disconnect the negative battery cable.
2. Collect the refrigerant. (See REFRIGERANT CHARGING).
3. Remove the air cleaner installation bolt and slide the air cleaner component
aside.
4. Remove the cooler hose (LO) installation nut, and then remove the cooler hose
(LO)
bracket from the vehicle stud bolt.

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.
5. Using the SSTs (49 B061 014, 49 G061 001) disconnect the cooler pipe and
cooler hose
from the A/C unit while not allowing the remaining compressor oil in the A/C
compressor and
pipes to spill. (See REFRIGERANT LINE REMOVAL/INSTALLATION).

6. Remove the following parts:
- Glove compartment (See GLOVE COMPARTMENT REMOVAL/INSTALLATION).
- Heat duct (RH) (See HEAT DUCT COMPONENT REMOVAL/INSTALLATION).
- Side wall (RH) (See SIDE WALL REMOVAL/INSTALLATION).
7. Disconnect the evaporator temperature sensor connector.
8. Remove the evaporator temperature sensor wiring harness clip.
9. Disconnect the resistor connector.
10. Make a hole in the position shown in the figure for the adhesive
polyurethane (2) and
remove the outlet pipe installation bolt.

11. Cut the adhesive polyurethane (2) near the contact surfaces of the
expansion valve and
outlet pipe, and tear it off.

12. Slide the outlet pipe to the right while being careful not to allow
remaining compressor
oil in the outlet pipe and expansion valve to spill.

13. Remove the expansion valve installation bolts.
14. Remove the expansion valve while being careful not to allow the remaining
compressor
oil in the expansion valve and evaporator to spill.
15. Tear off the adhesive polyurethane (2) from the expansion valve.
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.
16. Cut the adhesive polyurethane (2) as shown in the figure and remove the
adhesive
polyurethane (2) from the outlet pipe near the expansion valve.

EXPANSION VALVE INSTALLATION
1. Slide the outlet pipe to the right while being careful not to allow the
remaining compressor
oil in the outlet pipe to spill.

2. Install the expansion valve.
3. Install the outlet pipe.
4. Align the adhesive polyurethane (2) notch with the center of the lower
surface of the
expansion valve, and adhere.

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

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

7. Connect the resistor connector.
8. Install the evaporator temperature sensor wiring harness clip.
9. Connect the evaporator temperature sensor connector.
10. Install the following parts:
- Side wall (RH) (See SIDE WALL REMOVAL/INSTALLATION).
- Heat duct (RH) (See HEAT DUCT COMPONENT REMOVAL/INSTALLATION).
- Glove compartment (See GLOVE COMPARTMENT REMOVAL/INSTALLATION).
11. Connect the clutch pipe and cooler hose while being careful not to allow
the remaining oil
in the pipe and A/C unit to spill. (See REFRIGERANT LINE REMOVAL/INSTALLATION).

12. Install the cooler hose (LO) bracket.

Tightening torque
- 6.9-9.8 N*m {71-99 kgf*cm, 62-86 in*lbf}
13. Install the air cleaner component.
14. Charge the refrigerant. (See REFRIGERANT CHARGING).
15. Connect the negative battery cable.
16. Perform the refrigerant system performance test. (See REFRIGERANT SYSTEM
PERFORMANCE TEST).
READ NEXT:
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
HEAT DUCT COMPONENT REMOVAL/INSTALLATION
Heat Duct (LH)
1. Disconnect the negative battery cable.
2. Remove the following parts:
Rear console (See REAR CONSOLE REMOVAL/INSTALLATION).
Shift lever k
SEE MORE:
DRIVE BELT INSPECTION
NOTE:
Drive belt deflection/tension inspection is not necessary because of the
use of the drive
belt auto tensioner.
1. Remove the splash shield (RH).
2. Verify that the drive belt auto tensioner indicator mark does not exceed
the limit.
If it exceeds the limit, repla
WARNING:
When performing a road test, be aware of other vehicles, people,
impediments, etc. to avoid an accident.
NOTE:
When the legal speed limit must be exceeded, use a chassis dynamometer.
Road Test Preparation
1. Inspect the engine coolant. (See ENGINE COOLANT LEVEL INSPECTION).
2. Insp
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