Mazda Car 2002-04

Removal & Installation 1

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626



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  


CAUTION
After disconnecting the battery, wait for more than 1 minute for the SAS to deplete its stored energy.

  1. Drain the cooling system into a clean container for reuse.
  2.  
  3. Discharge and recover the air conditioning system refrigerant.
  4.  
  5. Place the wheel in the straight-ahead position and turn the ignition switch to LOCK.
  6.  
  7. At the driver-s side, remove the SAS module and the steering wheel removing or disconnecting the following:

    Cover clips at both sides of the steering wheel
     
    Steering wheel-to-SAS module bolts
     
    SAS module from the steering wheel and disconnect the electrical connector
     
    Steering wheel-to-column nut
     
    Steering wheel from the steering column using a suitable puller
     

  8.  
  9. At the passenger-s side, remove the SAS module by removing or disconnecting the following:

    Glove compartment and the glove compartment cover
     
    SAS module-to-dash bolts
     
    SAS module and disconnect the electrical connector
     

  10.  
  11. Remove the instrument cluster by removing or disconnecting the following:

    Instrument cluster meter hood
     
    Instrument cluster-to-dash screws, the instrument cluster and disconnect the electrical connectors
     

  12.  
  13. Remove the climate control assembly by removing or disconnecting the following:

    Climate control meter hood
     
    Climate control assembly screws
     
    Climate control assembly and disconnect the electrical connector and the assembly
     

  14.  
  15. Remove the audio unit by removing or disconnecting the following:

    Hole covers by inserting a small tape-wrapped flathead screwdriver into the slot and carefully pry off the hole covers
     
    Using 2 removal tools 49 UN01 050 or equivalent, insert them into sides of the audio unit.
     
    Slide audio unit outward and forward
     
    Electrical connectors and the antenna jack
     

  16.  
  17. Remove the instrument panel by removing or disconnecting the following:

    Upper center panel cover
     
    Dash panel-to-chassis bolts
     
    Dash panel with the help of an assistant
     

  18.  
  19. Remove the evaporator housing by removing or disconnecting the following:

    Center lower panel
     
    Refrigerant lines from the air conditioning evaporator and discard the gaskets
     
    Blower motor assembly, if necessary
     
    Evaporator assembly fasteners and remove the evaporator assembly
     

  20.  
  21. Remove or disconnect the following:

    Rear heater duct
     
    Heater housing fasteners and the heater housing
     
    Airflow mode actuator
     

  22.  
  23. Separate the heater housing and remove the heater core.
  24.  


    Click image to see an enlarged view

    Fig. Exploded view of the steering wheel and SAS module-626



    Click image to see an enlarged view

    Fig. Exploded view of the passenger-s side SAS module-626



    Click image to see an enlarged view

    Fig. View of the instrument cluster assembly-626



    Click image to see an enlarged view

    Fig. Removing the audio unit-626



    Click image to see an enlarged view

    Fig. View of the instrument panel assembly-626



    Click image to see an enlarged view

    Fig. View of the heater and air conditioning housing assemblies-626



    Click image to see an enlarged view

    Fig. Exploded view of the heater core and heater housing assembly-626


To install:

  1. Install the heater core and assemble the heater housing.
  2.  
  3. Install or connect the following:

    Airflow mode actuator
     
    Heater housing and the heater housing fasteners
     
    Rear heater duct
     

  4.  
  5. Install the evaporator housing by installing or connecting the following:

    Center lower panel
     
    Refrigerant lines to the air conditioning evaporator using new gaskets
     
    Blower motor assembly, if necessary
     
    Evaporator assembly and the evaporator assembly fasteners
     

  6.  
  7. Install the instrument panel by installing or connecting the following:

    Upper center panel cover
     
    Dash panel-to-chassis bolts
     
    Dash panel with the help of an assistant
     

  8.  
  9. Install the audio unit by installing or connecting the following:

    Hole covers
     
    Audio unit
     
    Electrical connectors and the antenna jack
     

  10.  
  11. Install the climate control assembly by installing or connecting the following:

    Climate control meter hood
     
    Climate control assembly screws
     
    Climate control assembly and connect the electrical connector
     

  12.  
  13. Install the instrument cluster by installing or connecting the following:

    Instrument cluster meter hood
     
    Instrument cluster-to-dash screws, the instrument cluster and connect the electrical connectors
     

  14.  
  15. At the passenger-s side, install the SAS module by installing or connecting the following:

    Glove compartment and the glove compartment cover
     
    SAS module-to-dash bolts
     
    SAS module and connect the electrical connector
     

  16.  
  17. At the driver-s side, install the SAS module and the steering wheel by installing or connecting the following:

    Steering wheel and the steering wheel-to-column nut. Torque the steering wheel nut to 29-36 ft. lbs. (40-49 Nm).
     
    SAS module to the steering wheel and connect the electrical connector. Torque the steering column-to-SAS module bolts to 70-104 inch lbs. (8-12 Nm).
     
    Steering wheel-to-SAS module clips
     
    Cover clips, at both sides of the steering wheel
     

  18.  
  19. Refill the cooling system.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Evacuate, charge and leak test the air conditioning system refrigerant.
  24.  
  25. Operate the engine to normal operating temperatures; then, check the climate control system and check for leaks.
  26.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the battery, wait for more than 1 minute for the SAS to deplete its stored energy.

  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Discharge and recover the air conditioning system refrigerant.
  8.  
  9. Place the wheel in the straight-ahead position and turn the ignition switch to LOCK.
  10.  
  11. At the driver-s side, remove the SAS module and the steering wheel removing or disconnecting the following:

    Cover clips at both sides of the steering wheel
     
    Steering wheel-to-SAS module bolts
     
    SAS module from the steering wheel and disconnect the electrical connector
     
    Steering wheel-to-column nut
     
    Steering wheel from the steering column using a suitable puller
     

  12.  
  13. At the passenger-s side, remove the SAS module by removing or disconnecting the following:

    Glove compartment and the glove compartment cover
     
    SAS module-to-dash bolts
     
    SAS module and disconnect the electrical connector
     

  14.  
  15. Remove the instrument cluster by removing or disconnecting the following:

    Instrument cluster meter hood
     
    Instrument cluster-to-dash screws, the instrument cluster and disconnect the electrical connectors
     

  16.  
  17. Remove the climate control assembly by removing or disconnecting the following:

    Climate control meter hood
     
    Climate control assembly screws
     
    Climate control assembly and disconnect the electrical connector and the assembly
     

  18.  
  19. Remove the audio unit by removing or disconnecting the following:

    Hole covers by inserting a small tape-wrapped flathead screwdriver into the slot and carefully pry off the hole covers
     
    Using 2 removal tools 49 UN01 050 or equivalent, insert them into sides of the audio unit.
     
    Slide audio unit outward and forward
     
    Electrical connectors and the antenna jack
     

  20.  
  21. Remove the instrument panel by removing or disconnecting the following:

    Upper center panel cover
     
    Dash panel-to-chassis bolts
     
    Dash panel with the help of an assistant
     

  22.  
  23. Remove the evaporator housing by removing or disconnecting the following:

    Center lower panel
     
    Refrigerant lines from the air conditioning evaporator and discard the gaskets
     
    Blower motor assembly, if necessary
     
    Evaporator assembly fasteners and remove the evaporator assembly
     

  24.  
  25. Remove or disconnect the following:

    Rear heater duct
     
    Heater housing fasteners and the heater housing
     
    Airflow mode actuator
     

  26.  
  27. Separate the heater housing and remove the heater core.

    Click image to see an enlarged view

    Fig. Exploded view of the steering wheel and SAS module-626



    Click image to see an enlarged view

    Fig. Exploded view of the passenger-s side SAS module-626



    Click image to see an enlarged view

    Fig. View of the instrument cluster assembly-626



    Click image to see an enlarged view

    Fig. Removing the audio unit-626



    Click image to see an enlarged view

    Fig. View of the instrument panel assembly-626



    Click image to see an enlarged view

    Fig. View of the heater and air conditioning housing assemblies-626



    Click image to see an enlarged view

    Fig. Exploded view of the heater core and heater housing assembly-626

  28.  

To install:

  1. Install the heater core and assemble the heater housing.
  2.  
  3. Install or connect the following:

    Airflow mode actuator
     
    Heater housing and the heater housing fasteners
     
    Rear heater duct
     

  4.  
  5. Install the evaporator housing by installing or connecting the following:

    Center lower panel
     
    Refrigerant lines to the air conditioning evaporator using new gaskets
     
    Blower motor assembly, if necessary
     
    Evaporator assembly and the evaporator assembly fasteners
     

  6.  
  7. Install the instrument panel by installing or connecting the following:

    Upper center panel cover
     
    Dash panel-to-chassis bolts
     
    Dash panel with the help of an assistant
     

  8.  
  9. Install the audio unit by installing or connecting the following:

    Hole covers
     
    Audio unit
     
    Electrical connectors and the antenna jack
     

  10.  
  11. Install the climate control assembly by installing or connecting the following:

    Climate control meter hood
     
    Climate control assembly screws
     
    Climate control assembly and connect the electrical connector
     

  12.  
  13. Install the instrument cluster by installing or connecting the following:

    Instrument cluster meter hood
     
    Instrument cluster-to-dash screws, the instrument cluster and connect the electrical connectors
     

  14.  
  15. At the passenger-s side, install the SAS module by installing or connecting the following:

    Glove compartment and the glove compartment cover
     
    SAS module-to-dash bolts
     
    SAS module and connect the electrical connector
     

  16.  
  17. At the driver-s side, install the SAS module and the steering wheel by installing or connecting the following:

    Steering wheel and the steering wheel-to-column nut. Torque the steering wheel nut to 29-36 ft. lbs. (40-49 Nm).
     
    SAS module to the steering wheel and connect the electrical connector. Torque the steering column-to-SAS module bolts to 70-104 inch lbs. (8-12 Nm).
     
    Steering wheel-to-SAS module clips
     
    Cover clips, at both sides of the steering wheel
     

  18.  
  19. Refill the cooling system.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Evacuate, charge and leak test the air conditioning system refrigerant.
  24.  
  25. Operate the engine to normal operating temperatures; then, check the climate control system and check for leaks.
  26.  

Removal And Installation
  1. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the battery, wait for more than 1 minute for the SAS to deplete its stored energy.

  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Discharge and recover the air conditioning system refrigerant.
  6.  
  7. Place the wheel in the straight-ahead position and turn the ignition switch to LOCK.
  8.  
  9. At the driver-s side, remove the SAS module and the steering wheel removing or disconnecting the following:

    Cover clips at both sides of the steering wheel
     
    Steering wheel-to-SAS module bolts
     
    SAS module from the steering wheel and disconnect the electrical connector
     
    Steering wheel-to-column nut
     
    Steering wheel from the steering column using a suitable puller
     

  10.  
  11. At the passenger-s side, remove the SAS module by removing or disconnecting the following:

    Glove compartment and the glove compartment cover
     
    SAS module-to-dash bolts
     
    SAS module and disconnect the electrical connector
     

  12.  
  13. Remove the instrument cluster by removing or disconnecting the following:

    Instrument cluster meter hood
     
    Instrument cluster-to-dash screws, the instrument cluster and disconnect the electrical connectors
     

  14.  
  15. Remove the climate control assembly by removing or disconnecting the following:

    Climate control meter hood
     
    Climate control assembly screws
     
    Climate control assembly and disconnect the electrical connector and the assembly
     

  16.  
  17. Remove the audio unit by removing or disconnecting the following:

    Hole covers by inserting a small tape-wrapped flathead screwdriver into the slot and carefully pry off the hole covers
     
    Using 2 removal tools 49 UN01 050 or equivalent, insert them into sides of the audio unit.
     
    Slide audio unit outward and forward
     
    Electrical connectors and the antenna jack
     

  18.  
  19. Remove the instrument panel by removing or disconnecting the following:

    Upper center panel cover
     
    Dash panel-to-chassis bolts
     
    Dash panel with the help of an assistant
     

  20.  
  21. Remove the evaporator housing by removing or disconnecting the following:

    Center lower panel
     
    Refrigerant lines from the air conditioning evaporator and discard the gaskets
     
    Blower motor assembly, if necessary
     
    Evaporator assembly fasteners and remove the evaporator assembly
     

  22.  
  23. Remove or disconnect the following:

    Rear heater duct
     
    Heater housing fasteners and the heater housing
     
    Airflow mode actuator
     

  24.  
  25. Separate the heater housing and remove the heater core.

    Click image to see an enlarged view

    Fig. Exploded view of the steering wheel and SAS module-1998-00 626



    Click image to see an enlarged view

    Fig. Exploded view of the passenger-s side SAS module-1998-00 626



    Click image to see an enlarged view

    Fig. View of the instrument cluster assembly-1998-00 626



    Click image to see an enlarged view

    Fig. Removing the audio unit-1998-00 626



    Click image to see an enlarged view

    Fig. View of the instrument panel assembly-1998-00 626



    Click image to see an enlarged view

    Fig. View of the heater and air conditioning housing assemblies-1998-00 626



    Click image to see an enlarged view

    Fig. Exploded view of the heater core and heater housing assembly-1998-00 626

  26.  

To install:

  1. Install the heater core and assemble the heater housing.
  2.  
  3. Install or connect the following:

    Airflow mode actuator
     
    Heater housing and the heater housing fasteners
     
    Rear heater duct
     

  4.  
  5. Install the evaporator housing by installing or connecting the following:

    Center lower panel
     
    Refrigerant lines to the air conditioning evaporator using new gaskets
     
    Blower motor assembly, if necessary
     
    Evaporator assembly and the evaporator assembly fasteners
     

  6.  
  7. Install the instrument panel by installing or connecting the following:

    Upper center panel cover
     
    Dash panel-to-chassis bolts
     
    Dash panel with the help of an assistant
     

  8.  
  9. Install the audio unit by installing or connecting the following:

    Hole covers
     
    Audio unit
     
    Electrical connectors and the antenna jack
     

  10.  
  11. Install the climate control assembly by installing or connecting the following:

    Climate control meter hood
     
    Climate control assembly screws
     
    Climate control assembly and connect the electrical connector
     

  12.  
  13. Install the instrument cluster by installing or connecting the following:

    Instrument cluster meter hood
     
    Instrument cluster-to-dash screws, the instrument cluster and connect the electrical connectors
     

  14.  
  15. At the passenger-s side, install the SAS module by installing or connecting the following:

    Glove compartment and the glove compartment cover
     
    SAS module-to-dash bolts
     
    SAS module and connect the electrical connector
     

  16.  
  17. At the driver-s side, install the SAS module and the steering wheel by installing or connecting the following:

    Steering wheel and the steering wheel-to-column nut. Torque the steering wheel nut to 29-36 ft. lbs. (40-49 Nm)
     
    SAS module to the steering wheel and connect the electrical connector. Torque the steering column-to-SAS module bolts to 70-104 inch lbs. (8-12 Nm)
     
    Steering wheel-to-SAS module clips
     
    Cover clips, at both sides of the steering wheel
     

  18.  
  19. Refill the cooling system.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Evacuate, charge and leak test the air conditioning system refrigerant.
  24.  
  25. Operate the engine to normal operating temperatures; then, check the climate control system and check for leaks.
  26.  

Mazda3



 
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