Attention! The models described in this manual are equipped with airbags. When working in the cushion area, always turn them off (see chapter 12) to avoid accidental operation. which may result in injury.
Attention! The air conditioning system is under pressure. Do not disconnect the system piping until it is discharged. The refrigerant must be properly removed and sent for regeneration to a service station or to a specialized station that has the appropriate equipment. Protect your eyes when disconnecting refrigerant lines.
Removing
1. Discharge the air conditioning system (to do this, contact a specialized station).
2. Disconnect the refrigerant pipes from the evaporator on the engine bulkhead (pic. 19.2). Depending on the model, this may require either conventional open end wrenches or a special tool for spring clamp couplings. Plug the openings immediately to protect the system from dirt and moisture.
3. On a Mazda model, remove the glove box and passenger side lower trim panel. On the Probe model, remove the instrument panel (see chapter 11).
4. Disconnect all electrical connectors from the evaporator and fan housings. On the Probe, also disconnect the cable from the throttle control lever.
5. Detach the evaporator housing from the engine bulkhead (pic. 19.5). On Probe models, the evaporator and fan housings are removed together, while on Mazda models, the evaporator housing can be removed without touching the fan.
6. Remove the screws connecting the halves of the evaporator body, separate the body and remove the core.
7. On Mazda models produced since 1997, disconnect the safety valve from the evaporator. Be careful not to damage the thin copper tube attached to the valve. Immediately plug all openings to protect the system from moisture and dirt.
8. Inspect the evaporator core and fittings for cracks, leaks, or other damage. If necessary, replace the evaporator.
Installation
9. Reinstall the relief valve, replacing the O-ring underneath. Reinstall the copper tube. Tighten valve connections securely.
10. The rest of the installation is carried out in the reverse order of removal. When replacing o-rings, keep in mind that the o-rings must match the type of refrigerant in your air conditioner. Do not lubricate the union nuts with compressor oil.
11. Take the system to a specialist station for charging and testing. If the evaporator is being replaced with a new one, add 90 ml of oil to the high pressure line of the compressor. Use only the type of oil that is compatible with your system's refrigerant.