Manifold And Tube Assembly Removal/Installation (4.0L)

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.

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.

Recover the refrigerant; see REFRIGERANT SYSTEM TESTS .
Remove the air cleaner assembly.
Remove the A/C compressor. See A/C COMPRESSOR REMOVAL/INSTALLATION (4.0L) .
Disconnect the pressure cut-off switch electrical connector.

Fig 1: Disconnecting Pressure Cut-Off Switch
Courtesy of MAZDA MOTORS CORP.
Disconnect the compressor manifold and tube assembly from the condenser core.
- Discard the O-ring seal.
Fig 2: Disconnecting Compressor Manifold & Tube Assembly From Condenser Core
Courtesy of MAZDA MOTORS CORP.
Disconnect the compressor manifold and tube assembly spring lock coupling from the suction accumulator. See SPRING LOCK COUPLING .
- Discard the O-ring seal.
Fig 3: Disconnecting Compressor Manifold & Tube Assembly Spring Lock Coupling From Suction Accumulator
Courtesy of MAZDA MOTORS CORP.
Raise and support the vehicle.
Remove the bolt and detach the compressor manifold and tube assembly.

Fig 4: Detaching Compressor Manifold & Tube Assembly
Courtesy of MAZDA MOTORS CORP.
Lower the vehicle.
Remove the compressor manifold and tube assembly.
To install, reverse the removal procedure.
- If a new compressor manifold and tube assembly is to be installed, transfer the pressure cutoff switch to the new compressor manifold and tube assembly.
- Lubricate the refrigerant system with the correct amount of clean refrigerant oil. See REFRIGERANT OIL ADDITION .
- Install new O-ring seals lubricated with clean refrigerant oil.
Evacuate, leak test, and charge the refrigerant system. See REFRIGERANT SYSTEM TESTS .