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A/C Compressor Removal/Installation (3.0L)

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:
  • When installing a new A/C compressor due to an internal failure of the old unit, you must carry out the following procedures to remove contamination from the air conditioning system:
  • If A/C flushing equipment is available, carry out the flushing of the air condition system prior to installing a new air conditioning compressor.
  • If A/C flushing equipment is not available, carry out the filtering of the air conditioning system after a new air conditioning compressor has been installed. See REFRIGERANT SYSTEM FILTERING AFTER A/C COMPRESSOR REPLACEMENT  .
  • Install a new evaporator core orifice as directed by the A/C flushing or filtering procedure. See EVAPORATOR CORE ORIFICE REMOVAL/INSTALLATION  .
  • Replace the receiver/drier. See RECEIVER/DRIER REMOVAL/INSTALLATION  .
NOTE: Replacement of the suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.
  1. If flushing the of the refrigerant system has not been performed, recover the refrigerant. See REFRIGERANT SYSTEM TESTS  .
  2. Reposition the air intake duct.
    1. Loosen the clamp.
    2. Disconnect the crankcase ventilation tube.
    3. Reposition the air intake duct.
    Fig 1: Installing Air Intake Duct
    G02673197Courtesy of MAZDA MOTORS CORP.
  3. Remove the accessory drive belt from the A/C compressor pulley. See BELT ROUTING .
  4. Disconnect the electrical connector.
    Fig 2: Disconnecting A/C Compressor Electrical Connector
    G02673198Courtesy of MAZDA MOTORS CORP.
  5. Remove the clamp nut on the compressor manifold and tube assembly.
    Fig 3: Removing A/C Compressor Manifold & Tube Assembly
    G02673199Courtesy of MAZDA MOTORS CORP.
  6. Loosen the bolt and disconnect the compressor manifold and tube assembly from the A/C compressor.
    Fig 4: Disconnecting A/C Compressor Manifold & Tube Assembly
    G02673200Courtesy of MAZDA MOTORS CORP.
  7. Remove the bolts and the A/C compressor.
    • Discard the O-ring seals.
    Fig 5: Removing A/C Compressor
    G02673201Courtesy of MAZDA MOTORS CORP.
  8. To install, reverse the removal procedure.
    • If a new A/C compressor is to be installed, the A/C compressor clutch field coil and the A/C clutch plate must be transferred from the old unit. See MAGNETIC CLUTCH REMOVAL/INSTALLATION  .
    • If filtering the refrigerant system is not to be performed, lubricate the refrigerant system with the correct amount of clean refrigerant oil. See REFRIGERANT OIL ADDITION  .
    • Evacuate, leak test, and charge the refrigerant system. See REFRIGERANT SYSTEM TESTS  .
    • Install new O-ring seals lubricated in clean refrigerant oil.
  9. If filtering the refrigerant system is not to be performed, evacuate, leak test, and charge the refrigerant system. See REFRIGERANT SYSTEM TESTS  .
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