A/C Compressor Removal / Installation - 4.0L

Fig 1: Removing /Installing A/C Compressor With Torque Specifications (4.0L)

Courtesy of MAZDA MOTORS CORP.

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 A/C 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 as directed by the A/C flushing or filtering procedure. See A/C 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 of the refrigerant system has not been performed, recover the refrigerant. See A/C REFRIGERANT SYSTEM TESTS .
2. Remove the accessory drive belt from the A/C compressor pulley. See DRIVE BELT REMOVAL / INSTALLATION - 4.0L .
3. Remove the bolts and detach the power steering fluid reservoir.
   Fig 2: Removing Power Steering Fluid Reservoir

   Courtesy of MAZDA MOTORS CORP.
4. Remove the bolts and the bracket.
   Fig 3: Removing Bolts And Bracket

   Courtesy of MAZDA MOTORS CORP.
5. Disconnect the electrical connector.
   Fig 4: Disconnecting Electrical Connector

   Courtesy of MAZDA MOTORS CORP.
6. Loosen the bolt and disconnect the compressor manifold and tube assembly from the A/C compressor.
   Fig 5: Loosening/Tightening Bolt With Torque Specifications

   Courtesy of MAZDA MOTORS CORP.
7. Remove the pin-type retainers and position the inner fender well access cover aside.
   Fig 6: Removing Pin-Type Retainers

   Courtesy of MAZDA MOTORS CORP.
   NOTE:

   • The two lower nuts and studs are accessible through the inner fender well.
8. Remove the four nuts, four studs, and the A/C compressor.
   • Discard the O-ring seals.
9. 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 A/C COMPRESSOR MAGNETIC CLUTCH REMOVAL / INSTALLATION  .
   • Lubricate the refrigerant system with the correct amount of clean refrigerant oil. See A/C REFRIGERANT OIL ADDITION .
   • Evacuate, leak test, and charge the refrigerant system. See A/C REFRIGERANT SYSTEM TESTS .
   • Install new O-ring seals lubricated in clean refrigerant oil.
10. Evacuate, leak test, and charge the refrigerant system. See A/C REFRIGERANT SYSTEM TESTS .