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Inspection And Assembly Requirements - Following Compressor Failure

WARNING: This page is about a different car, the 2002 Mazda B4000, 2002 Mazda B3000, and 2002 Mazda B2300. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: To prevent refrigerant system contamination and possible failure of the replacement A/C compressor, perform the following procedures.
NOTE: A dirty evaporator core orifice or a condenser to evaporator tube containing black refrigerant oil and particles indicates that the A/C compressor has failed and must be replaced.
  1. Remove and discard the evaporator core orifice; see EVAPORATOR CORE ORIFICE REMOVAL/INSTALLATION  .
  2. Remove the A/C compressor; see A/C COMPRESSOR REMOVAL/INSTALLATION (3.0L)  or A/C COMPRESSOR REMOVAL/INSTALLATION (4.0L)  .
    1. Drain the residual refrigerant oil from the A/C compressor and measure the volume for proper system oil matching; see REFRIGERANT OIL ADDITION  .
    3. NOTE: The suction accumulator/drier and A/C evaporator core orifice cannot be cleaned and a new A/C evaporator core office must be installed.
  3. Remove the suction accumulator/drier; see RECEIVER/DRIER REMOVAL/INSTALLATION  .
    1. Completely drain the residual refrigerant oil from the receiver/drier (see REFRIGERANT OIL ADDITION  ) and measure the volume for proper oil system matching.
    4. NOTE: System flushing is the preferred method of cleaning. However, if flushing equipment is not available, perform system filtering.
  4. Perform an A/C system flushing or filtering procedure:
    • If A/C system flushing equipment is available, clean the evaporator core and the condenser core by flushing. Follow the instructions included with the flushing equipment.
      NOTE: System flushing must be performed prior to the installation of the replacement A/C compressor. Flush only the evaporator core and condenser core. Do not flush the receiver/drier, evaporator core orifice, hoses and mufflers. Hoses can be reused unless they contain debris.

      If A/C system flushing equipment is not available, perform the refrigerant system filtering after A/C compressor replacement procedure; see REFRIGERANT SYSTEM FILTERING AFTER A/C COMPRESSOR REPLACEMENT  .

  5. Install the replacement A/C compressor; see A/C COMPRESSOR REMOVAL/INSTALLATION (3.0L)  or A/C COMPRESSOR REMOVAL/INSTALLATION (4.0L)  .
  6. Install the replacement receiver/drier; see RECEIVER/DRIER REMOVAL/INSTALLATION  .
  7. Install the replacement evaporator core orifice; see EVAPORATOR CORE ORIFICE REMOVAL/INSTALLATION  .
  8. Properly oil match the system; see REFRIGERANT OIL ADDITION  .
  9. Evacuate and charge the system; see REFRIGERANT SYSTEM TESTS  .
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