Mazda Car 2002-04

Removal & Installation 6

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Millenia



  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. At the driver-s side, remove the SAS module and the steering wheel by removing or disconnecting the following:

    Place the wheel in the straight-ahead position and turn the ignition switch to LOCK
     
    Cover clips at both sides of the steering wheel
     
    Steering wheel-to-SAS module clips
     
    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
     

  6.  
  7. 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
     

  8.  
  9. Remove the rear console by removing or disconnecting the following:

    Rear console-s box
     
    Bake boot
     
    Center panel
     
    Rear console
     

  10.  
  11. Remove or disconnect the following:

    A-pillar trim at both sides
     
    Undercover at the passenger-s side
     
    Upper and lower steering column covers
     
    Electrical connectors and remove the combination switch from the steering column
     
    Meter hood
     
    Electrical connectors and remove the instrument cluster
     
    Steering column-to-chassis bolts and the steering column
     
    Hood release lever
     
    Both side panels
     
    Instrument panel with the help of an assistant
     

  12.  
  13. Remove the evaporator housing by removing or disconnecting the following:

    Air conditioning system refrigerant lines and discard the gaskets
     
    Aspirator hose
     
    Power transistor connector
     
    MAX-HI connector
     
    Evaporator temperature connector
     
    Evaporator housing assembly
     

  14.  
  15. Disconnect and remove the heater unit assembly.
  16.  
  17. Separate the heater unit cases and remove the heater core.
  18.  


    Click image to see an enlarged view

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



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Exploded view of the steering wheel and steering column assembly-Millenia



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and rear console assemblies-Millenia



    Click image to see an enlarged view

    Fig. Exploded view of the heater core and heater case assembly-Millenia


To install:

  1. Install the heater core and assemble the heater unit cases.
  2.  
  3. Connect and install the heater unit assembly.
  4.  
  5. Install the evaporator housing by installing or connecting the following:

    Evaporator housing assembly
     
    Evaporator temperature connector
     
    MAX-HI connector
     
    Power transistor connector
     
    Aspirator hose
     
    Air conditioning system refrigerant lines using new gaskets
     

  6.  
  7. Install or connect the following:

    Instrument panel with the help of an assistant
     
    Both side panels
     
    Hood release lever
     
    Steering column and the steering column-to-chassis bolts
     
    Instrument cluster and connect the electrical connectors
     
    Meter hood
     
    Combination switch to the steering column and connect the electrical connectors
     
    Upper and lower steering column covers
     
    Undercover at the passenger-s side
     
    A-pillar trim at both sides
     

  8.  
  9. Install the rear console by installing or connecting the following:

    Rear console
     
    Center panel
     
    Brake boot
     
    Rear console-s box
     

  10.  
  11. At the passenger-s side, install the SAS module by installing or connecting the following:

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

  12.  
  13. At the driver-s side, install the SAS module and the steering wheel by installing or connecting the following:

    Steering wheel to the steering column
     
    Steering wheel-to-column nut. Torque the nut to 29-36 ft. lbs. (40-49 Nm).
     
    SAS module to the steering wheel and connect the electrical connector. Torque the bolts to 79-113 inch lbs. (9-13 Nm).
     
    Steering wheel-to-SAS module clips
     
    Cover clips at both sides of the steering wheel
     

  14.  
  15. Refill the cooling system.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Evacuate, charge and leak test the air conditioning system refrigerant.
  20.  
  21. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  22.  

  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. At the driver-s side, remove the SAS module and the steering wheel by removing or disconnecting the following:

    Place the wheel in the straight-ahead position and turn the ignition switch to LOCK
     
    Cover clips at both sides of the steering wheel
     
    Steering wheel-to-SAS module clips
     
    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 rear console by removing or disconnecting the following:

    Rear console-s box
     
    Bake boot
     
    Center panel
     
    Rear console
     

  14.  
  15. Remove or disconnect the following:

    A-pillar trim at both sides
     
    Undercover at the passenger-s side
     
    Upper and lower steering column covers
     
    Electrical connectors and remove the combination switch from the steering column
     
    Meter hood
     
    Electrical connectors and remove the instrument cluster
     
    Steering column-to-chassis bolts and the steering column
     
    Hood release lever
     
    Both side panels
     
    Instrument panel with the help of an assistant
     

  16.  
  17. Remove the evaporator housing by removing or disconnecting the following:

    Air conditioning system refrigerant lines and discard the gaskets
     
    Aspirator hose
     
    Power transistor connector
     
    MAX-HI connector
     
    Evaporator temperature connector
     
    Evaporator housing assembly
     

  18.  
  19. Disconnect and remove the heater unit assembly.
  20.  
  21. Separate the heater unit cases and remove the heater core.

    Click image to see an enlarged view

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



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Exploded view of the steering wheel and steering column assembly-Millenia



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and rear console assemblies-Millenia



    Click image to see an enlarged view

    Fig. Exploded view of the heater core and heater case assembly-Millenia

  22.  

To install:

  1. Install the heater core and assemble the heater unit cases.
  2.  
  3. Connect and install the heater unit assembly.
  4.  
  5. Install the evaporator housing by installing or connecting the following:

    Evaporator housing assembly
     
    Evaporator temperature connector
     
    MAX-HI connector
     
    Power transistor connector
     
    Aspirator hose
     
    Air conditioning system refrigerant lines using new gaskets
     

  6.  
  7. Install or connect the following:

    Instrument panel with the help of an assistant
     
    Both side panels
     
    Hood release lever
     
    Steering column and the steering column-to-chassis bolts
     
    Instrument cluster and connect the electrical connectors
     
    Meter hood
     
    Combination switch to the steering column and connect the electrical connectors
     
    Upper and lower steering column covers
     
    Undercover at the passenger-s side
     
    A-pillar trim at both sides
     

  8.  
  9. Install the rear console by installing or connecting the following:

    Rear console
     
    Center panel
     
    Brake boot
     
    Rear console-s box
     

  10.  
  11. At the passenger-s side, install the SAS module by installing or connecting the following:

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

  12.  
  13. At the driver-s side, install the SAS module and the steering wheel by installing or connecting the following:

    Steering wheel to the steering column
     
    Steering wheel-to-column nut. Torque the nut to 29-36 ft. lbs. (40-49 Nm).
     
    SAS module to the steering wheel and connect the electrical connector. Torque the bolts to 79-113 inch lbs. (9-13 Nm).
     
    Steering wheel-to-SAS module clips
     
    Cover clips at both sides of the steering wheel
     

  14.  
  15. Refill the cooling system.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Evacuate, charge and leak test the air conditioning system refrigerant.
  20.  
  21. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  22.  

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. At the driver-s side, remove the SAS module and the steering wheel by removing or disconnecting the following:

    Place the wheel in the straight-ahead position and turn the ignition switch to LOCK
     
    Cover clips at both sides of the steering wheel
     
    Steering wheel-to-SAS module clips
     
    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 rear console by removing or disconnecting the following:

    Rear console-s box
     
    Bake boot
     
    Center panel
     
    Rear console
     

  12.  
  13. Remove or disconnect the following:

    A-pillar trim at both sides
     
    Undercover at the passenger-s side
     
    Upper and lower steering column covers
     
    Electrical connectors and remove the combination switch from the steering column
     
    Meter hood
     
    Electrical connectors and remove the instrument cluster
     
    Steering column-to-chassis bolts and the steering column
     
    Hood release lever
     
    Both side panels
     
    Instrument panel with the help of an assistant
     

  14.  
  15. Remove the evaporator housing by removing or disconnecting the following:

    Air conditioning system refrigerant lines and discard the gaskets
     
    Aspirator hose
     
    Power transistor connector
     
    MAX-HI connector
     
    Evaporator temperature connector
     
    Evaporator housing assembly
     

  16.  
  17. Disconnect and remove the heater unit assembly.
  18.  
  19. Separate the heater unit cases and remove the heater core.

    Click image to see an enlarged view

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



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Exploded view of the steering wheel and steering column assembly-Millenia



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and rear console assemblies-Millenia



    Click image to see an enlarged view

    Fig. Exploded view of the heater core and heater case assembly-Millenia

  20.  

To install:

  1. Install the heater core and assemble the heater unit cases.
  2.  
  3. Connect and install the heater unit assembly.
  4.  
  5. Install the evaporator housing by installing or connecting the following:

    Evaporator housing assembly
     
    Evaporator temperature connector
     
    MAX-HI connector
     
    Power transistor connector
     
    Aspirator hose
     
    Air conditioning system refrigerant lines using new gaskets
     

  6.  
  7. Install or connect the following:

    Instrument panel with the help of an assistant
     
    Both side panels
     
    Hood release lever
     
    Steering column and the steering column-to-chassis bolts
     
    Instrument cluster and connect the electrical connectors
     
    Meter hood
     
    Combination switch to the steering column and connect the electrical connectors
     
    Upper and lower steering column covers
     
    Undercover at the passenger-s side
     
    A-pillar trim at both sides
     

  8.  
  9. Install the rear console by installing or connecting the following:

    Rear console
     
    Center panel
     
    Brake boot
     
    Rear console-s box
     

  10.  
  11. At the passenger-s side, install the SAS module by installing or connecting the following:

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

  12.  
  13. At the driver-s side, install the SAS module and the steering wheel by installing or connecting the following:

    Steering wheel to the steering column
     
    Steering wheel-to-column nut. Torque the nut to 29-36 ft. lbs. (40-49 Nm)
     
    SAS module to the steering wheel and connect the electrical connector. Torque the bolts to 79-113 inch lbs. (9-13 Nm)
     
    Steering wheel-to-SAS module clips
     
    Cover clips at both sides of the steering wheel
     

  14.  
  15. Refill the cooling system.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Evacuate, charge and leak test the air conditioning system refrigerant.
  20.  
  21. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  22.  

MX-6



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. At the driver-s side, remove the SAS module and the steering wheel by removing or disconnecting the following:

    Place the wheel in the straight-ahead position and turn the ignition switch to LOCK
     
    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.

    Click image to see an enlarged view

    Fig. Exploded view of the steering wheel and SAS module-1998-00 MX-6



    Click image to see an enlarged view

    Fig. Exploded view of the passenger-s side SAS module-1998-00 MX-6



    Click image to see an enlarged view

    Fig. View of the instrument cluster assembly-1998-00 MX-6



    Click image to see an enlarged view

    Fig. Removing the audio unit-1998-00 MX-6



    Click image to see an enlarged view

    Fig. View of the instrument panel assembly-1998-00 MX-6



    Click image to see an enlarged view

    Fig. View of the heater and air conditioning housing assemblies-1998-00 MX-6



    Click image to see an enlarged view

    Fig. Exploded view of the heater core and heater housing assembly-1998-00 MX-6

  24.  

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 aid 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. (7. 9-11.7 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.  

 
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