Mazda Car 2002-04

Removal & Installation 1

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  1. Before servicing the vehicle, refer to the precautions section.
    NOTE
    Refer the exploded view illustration for component locations and if applicable, their retainer torque specifications.

  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Discharge the refrigerant from the system.
  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Remove the dynamic chamber.
  10.  
  11. Remove the glove box as follows:
    1. Remove the damper clip.
    2.  
    3. Bend the stoppers in to disengage them.
    4.  
    5. Lower the glove box door and remove the clips by pulling straight out and remove the glove box.
    6.  

  12.  
  13. Remove the console as follows:
    1. If equipped with a manual transmission, remove the shifter knob.
    2.  
    3. Remove the panels (1 and 2) with a tape wrapped prytool, make sure to disconnect the cigarette lighter and ashtray illumination connections on panel 2.
    4.  
    5. Remove the bolts, disconnect the socket connector and remove the console.

      Click image to see an enlarged view

      Fig. Exploded view of the console assembly-Mazda6 and Mazdaspeed6 models

    6.  

  14.  
  15. Remove the meter hood as follows:
    1. Remove the screws, pull the meter hood outwards and detach the column cover.
    2.  

  16.  
  17. Remove the instrument cluster as follows:
    1. Lower the tilt steering wheel to its lowest point.
    2.  
    3. Pull the steering wheel towards you.
    4.  
    5. Remove the screws, connectors and cluster.
    6.  

  18.  
  19. Remove the column cover.
  20.  
  21. Remove the lower panel as follows:
    1. Pull the hood release lever.
    2.  
    3. While pushing the tab in the direction illustrated, using a tape wrapped small flat prytool to pull the release lever outwards from the lower panel.

      Click image to see an enlarged view

      Fig. Hood release lever removal-Mazda6 and Mazdaspeed6 models



      Click image to see an enlarged view

      Fig. Lower panel mounting-Mazda6 and Mazdaspeed6 models

    4.  
    5. Remove the lower panel screws.
    6.  
    7. Pull the panel out to disengage the clips A from the tabs B and remove the panel.
    8.  

  22.  
  23. Remove the steering shaft as follows:
    WARNING
    Handling the air bag module improperly can accidentally operate (deploy) the air bag module, which may seriously injure you.



    Click image to see an enlarged view

    Fig. Exploded view of the steering column and shaft assembly-Mazda6 and Mazdaspeed6 models

    1. Remove the air bag cover.
    2.  
    3. Remove the bolt.
    4.  
    5. Using a flathead screwdriver, pry out the connector stopper plate and unplug the connector.
    6.  
    7. Remove the drivers side air bag module.
    8.  
    9. Remove the lockbolt.
      WARNING
      Handling the air bag module improperly can accidentally deploy the air bag module, which may seriously injure you.

    10.  
    11. Remove the locknut.
      CAUTION
      Do not try to remove the steering wheel by hitting the shaft with a hammer. The column will collapse.

    12.  
    13. Set the vehicle in the straight-ahead position.
    14.  
    15. Remove the steering wheel using a suitable puller.
    16.  
    17. Remove the column cover.
    18.  
    19. Remove the clock spring connector.
    20.  
    21. Remove the screw.
    22.  
    23. Remove the clock spring.
    24.  
    25. Remove the combination switch.
    26.  
    27. Remove the steering shaft.
    28.  

  24.  
  25. Remove the A-pillar trim as follows:
    1. Partially pull back the seaming welt.
    2.  
    3. Gently pull the trim the disengage the clips A and then B (1).
    4.  
    5. Pull gently upwards on the trim to disengage clip B (2).
    6.  
    7. Disengage the tabs and remove the trim.

      Click image to see an enlarged view

      Fig. Exploded view of the A-trim mounting-Mazda6 and Mazdaspeed6 models



      Click image to see an enlarged view

      Fig. Exploded view of the front scuff plate mounting-Mazda6 and Mazdaspeed6 models

    8.  

  26.  
  27. Remove the front scuff plates as follows:
    1. Pull the scuff plate upwards and disengage clips (B), pins (C and D) and tabs (E).
    2.  
    3. Remove the scuff plate.
    4.  

  28.  
  29. Remove the front side trims as follows:
    1. Partially pull back the seaming welt.
    2.  
    3. Pull the trim outwards to disengage clip (A) and the stud bolt, then remove the trim.
    4.  

  30.  
  31. Remove the side panels using a flat bladed pry tool to disengage the clips.

    Click image to see an enlarged view

    Fig. Exploded view of the front side trim mounting-Mazda6 and Mazdaspeed6 models

  32.  
  33. If equipped with a wire type climate control unit, disconnect the wires for the front A/C unit as follows:
    1. Remove the illumination bulb.
    2.  
    3. Remove the unit.
    4.  
    5. Remove the fan switch.
    6.  
    7. Disassemble the wire as illustrated.

      Click image to see an enlarged view

      Fig. If equipped with a wire type climate control unit, disconnect the wires for the front A/C unit as shown-Mazda6 and Mazdaspeed6 models

    8.  

  34.  
  35. Disconnect the dashboard wiring harness connectors.
  36.  
  37. Remove the dashboard bolts and pull the dashboard pins out from the body.
    WARNING
    When removing the dashboard, make sure to support the dashboard is properly supported to avoid injury and also to avoid damage to the dashboard.

  38.  
  39. Remove the dashboard through the drivers side door.

    Click image to see an enlarged view

    Fig. Block type refrigerant joint-Mazda6 and Mazdaspeed6 models

  40.  
  41. Remove the blower motor.

    Click image to see an enlarged view

    Fig. Exploded view of the dashboard mounting-Mazda6 and Mazdaspeed6



    Click image to see an enlarged view

    Fig. Exploded view of the A/C unit assembly-Mazda6



    Click image to see an enlarged view

    Fig. Exploded view of the A/C unit assembly-Mazdaspeed6

  42.  

To install:

  1. Installation is the reverse of removal, keep in mind the following:
    1. Adjust the clock spring as follows:
      CAUTION
      If the clock spring is not adjusted, the spring wire in the clock spring could over-wind and break when the steering wheel is turned. Always adjust the clock spring after installing it.


      CAUTION
      The clock spring will break if over-wound. Do not forcibly turn the clock spring.



      Set the front tires straight-ahead
       



      Turn the clock spring clockwise until it stops

      Click image to see an enlarged view

      Fig. Turn the clock spring clockwise until it stops-Mazda6 and Mazdaspeed6



      Click image to see an enlarged view

      Fig. From the stopped position, turn the clock spring counterclockwise 2 3/4 turns-Mazda6 and Mazdaspeed6



      Click image to see an enlarged view

      Fig. Align the marks on the clock spring-Mazda6 and Mazdaspeed6

       
      From the stopped position, turn the clock spring counterclockwise 2 3 / 4 turns
       
      Align the marks
       
      Verify that the tilt / telescope lever is in the LOCK position
       

    2.  
    3. Tighten the steering shaft bolts A, nut B and nut C in that order.

      Click image to see an enlarged view

      Fig. Tighten the steering shaft bolts A, nut B and nut C in that order-Mazda6 and Mazdaspeed6

    4.  
    5. If equipped with a wire type climate control unit, connect the wires for the front A/C unit as illustrated.

      Click image to see an enlarged view

      Fig. If equipped with a wire type climate control unit, connect the wires for the front A/C unit as shown-Mazda6 and Mazdaspeed6 models

    6.  

  2.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the dashboard under cover.
  6.  
  7. Disconnect the blower motor connector.
  8.  
  9. Remove the blower motor.
  10.  

To install:

  1. Installation is the reverse of removal.
  2.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the bracket.
  4.  
  5. Remove the blower motor
  6.  

To install:

  1. Installation is the reverse of removal.

    Click image to see an enlarged view

    Fig. Blower motor mounting-Miata

  2.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the dashboard under cover.
  6.  
  7. Disconnect the blower motor connector and air hose.
  8.  
  9. Remove the blower motor.
  10.  

To install:

  1. Installation is the reverse of removal.
  2.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the glove box.
  4.  
  5. Unplug the connector and remove the blower motor
  6.  

To install:

  1. Installation is the reverse of removal.

    Click image to see an enlarged view

    Fig. Blower motor mounting-Protégé

  2.  

  1. Set the air intake mode to FRESH.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove or disconnect the following:
  6.  
  7. Right side front side trim.
  8.  
  9. Right side front scuff plate.
  10.  
  11. Decoration panel.
  12.  
  13. Glove compartment.

    Click image to see an enlarged view

    Fig. Exploded view of the blower motor assembly-Mazda 3

  14.  
  15. Passenger junction box and bracket.
  16.  
  17. Cut off the temporary steering stay on the passenger-s side.
  18.  
  19. Detach the hood release lever from the lower panel.
  20.  
  21. Remove the front scuff plate.
  22.  
  23. Remove the front side trim.
  24.  
  25. Remove the lower panel.
  26.  
  27. Remove the screws and slide the blower case out.
  28.  
  29. Disconnect the air intake actuator connector.
  30.  
  31. Remove the blower case.
  32.  
  33. Remove the air guide.
  34.  
  35. Install the tool 49 B061 015 to the blower motor. Align the SST guide with the sirocco fan clip position and press the tool tabs into the three set holes on the blower motor until they are inserted. Rotate the tool clockwise to lock the tool and blower motor.

    Click image to see an enlarged view

    Fig. Install the tool 49 B061 015 to the blower motor-Mazda 3

  36.  
  37. Disconnect the resistor connector if equipped with a manual air conditioner.
  38.  
  39. Disconnect the blower motor cooling pipe connected to the blower motor.
  40.  
  41. Remove the airflow mode actuator.
  42.  
  43. Disconnect the blower motor connector.
  44.  
  45. Remove the blower motor cover by pulling the lock on the top of the blower motor cover and rotating the blower motor cover.
    CAUTION
    When the blower motor cover is removed, the blower motor could fall in the A/C unit case causing the sirocco fan to be damaged. Therefore another person must hold the blower motor at the installation position. To prevent damage to the sirocco fan, pull the blower motor out being careful that the blower motor does not interfere with the A/C unit.

  46.  
  47. Remove the blower motor by pulling it out.
  48.  

To install:

  1. Installation is the reverse of removal, please note the following:
    NOTE
    Position the blower motor projection upward and install the blower motor to the A/C unit.


    CAUTION
    To prevent damage to the sirocco fan, install the blower motor being careful that the blower motor does not interfere with the A/C unit. Also, another person must hold the blower motor at the installation position.

    1. Install the tool to the blower motor.
    2.  
    3. Install the blower motor with the tool installed, to the A/C unit.
    4.  
    5. Install the blower motor cover from the driver-s side. Rotate the blower motor cover until a click is heard.

      Click image to see an enlarged view

      Fig. Rotate the blower motor cover until a click is heard-Mazda 3

    6.  
    7. Connect the blower motor connector.
    8.  
    9. Install the blower motor cooling pipe.
    10.  
    11. Remove the tool from the blower motor.
    12.  

  2.  
  3. If not replacing the blower case, replace the adhesive polyurethane on the fresh-air inlet of the blower case.
    CAUTION
    To adhere new polyurethane properly, be sure to remove the adhesive agent and adhesive polyurethane completely.


    NOTE
    If the blower case is removed or installed, the adhesive polyurethane can be damaged. Damaged adhesive polyurethane could cause abnormal noise or other malfunctions, therefore replace it.

    1. Insert the screw into the blower case and install the case to the A/C unit.
    2.  
    3. Install the blower case by inserting and rotating it in the directions of the arrows shown in the illustration

      Click image to see an enlarged view

      Fig. Install the blower case by inserting and rotating it in the directions of the arrows-Mazda 3

    4.  

  4.  

 
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