Mazda Car 2002-04

Instrument Panel, Pad, and Dashboard 1

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Instrument Panel



Removal & Installation
Mazda3
  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. Remove the battery cover.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Discharge the refrigerant from the system.
  8.  
  9. Drain and recycle the engine coolant.
  10.  
  11. Remove the front doors.
    CAUTION
    If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise or other malfunction could occur. Always plug open fittings immediately after removing any refrigeration cycle parts.



    Click image to see an enlarged view

    Fig. Cooler and heater hose connections at the firewall-Mazda3

  12.  
  13. To disconnect the different types of refrigerant line connectors, perform the following
    1. On block joint types. disconnect the block joint type pipes by grasping female side of the block with pliers or similar tool and holding firmly, then remove the connection bolt or nut.

      Click image to see an enlarged view

      Fig. Block type refrigerant joint-Mazda3



      Click image to see an enlarged view

      Fig. Spring lock type refrigerant joint-Mazda3



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      Fig. Looking through the inspection hole of the tool, insert the protruding part of the tool until it makes contact with the cage on spring lock type refrigerant joints-Mazda3

    2.  
    3. On spring-lock coupling type , set the service tool shown in the illustration and while looking through the inspection hole of the tool , insert the protruding part of the tool until it makes contact with the cage section. Use the tool to disconnect the male pipe or hose from the female by pulling the male pipe or hose.
      NOTE
      The male pipe or hose can be disconnected easily from the female pipe by pulling from the male pipe or hose while maintaining the pressure of the protruding part of the tool.

    4.  

  14.  
  15. Disconnect the heater hose at the firewall.
  16.  
  17. Remove the console as follows:
    1. Detach clips A, B and C and remove the upper panel.
    2.  
    3. Detach clips D, E and F and remove the boot panel.

      Click image to see an enlarged view

      Fig. Detach clips A, B and C and remove the console upper panel-Mazda3



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      Fig. Detach clips D, E and F and remove the boot panel from the console-Mazda3



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      Fig. Remove the remaining screws and clips from the console-Mazda3

    4.  
    5. Remove screws.
    6.  
    7. Detach clips G.
    8.  
    9. Disconnect the cigarette lighter connector.
    10.  
    11. Remove the ashtray illumination, then remove the ashtray panel.
    12.  
    13. Remove the screws B.
    14.  
    15. Detach tabs H and remove the console.
    16.  

  18.  
  19. Remove the shift lever component on models with a manual transmission as follows:
    1. Remove the battery and battery tray
    2.  
    3. Remove the center console.
    4.  
    5. Remove the front heat insulator.
    6.  
    7. Remove the shift lever knob.
    8.  
    9. Remove the boot panel.
    10.  
    11. Remove the nuts.
    12.  
    13. Remove the nut.
    14.  
    15. Remove the bracket.
    16.  
    17. Remove the seal plate.

      Click image to see an enlarged view

      Fig. Exploded view of the shift lever component on models with a manual transmission-Mazda3



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      Fig. Remove both the shift cable end and select cable end using a fastener remover-Mazda3

    18.  
    19. Remove both the shift cable end and select cable end using a fastener remover.
    20.  
    21. Remove the nuts.
    22.  
    23. Remove the shift lever component.
    24.  

  20.  
  21. Remove the shift lever component on models with an automatic transmission as follows:

    Click image to see an enlarged view

    Fig. Exploded view of the shift lever component on models with an automatic transmission-Mazda3

    1. Remove the battery cover.
    2.  
    3. Disconnect the negative battery cable.
    4.  
    5. Remove the battery, battery box and battery tray.
    6.  
    7. Remove the air cleaner component.
    8.  
    9. Remove the console.
    10.  
    11. Remove the front and center heat insulator.
    12.  
    13. Remove the selector lever component connector.
    14.  
    15. Remove the clip and selector cable.

      Click image to see an enlarged view

      Fig. Remove the clip and selector cable on models with an automatic transmission-Mazda3

    16.  
    17. Remove the selector lever component.
    18.  

  22.  
  23. Pull the decoration panel outward and detach the clips A and tab B in the order shown in the illustration.
  24.  
  25. Remove the decoration panel.
  26.  
  27. Pull the front scuff plate upward, detach clips A, locator pins B and C from the body, and then remove the front scuff plate.
  28.  
  29. Remove the front side trim fastener.
  30.  
  31. Pull the front side trim in the direction of the arrow and detach clip A and locator pin B.
  32.  
  33. Remove the glove box screws.
  34.  
  35. Pull the glove compartment outward and detach clips A and tab B.
  36.  
  37. Remove the glove compartment.

    Click image to see an enlarged view

    Fig. Exploded view of the front side trim assembly-Mazda3



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    Fig. Exploded view of the shower duct assembly-Mazda3

  38.  
  39. Remove the shower ducts.
  40.  
  41. Remove the Passenger Junction Box (PJB) as follows:
    1. Remove the cover.
    2.  
    3. On connector A, push the release tab in the direction of the arrow, then rotate the lever in the direction of the arrow and remove connector A.
    4.  
    5. On connector B, rotate the lever in the direction of the arrow and remove connector B.
    6.  
    7. Turn the screws counterclockwise to remove the PJB.
      NOTE
      The screws cannot be removed from the PJB.

    8.  
    9. Remove the PJB as shown in the illustration.

      Click image to see an enlarged view

      Fig. Exploded view of the passenger junction box assembly-Mazda3



      Click image to see an enlarged view

      Fig. On connector A, push the release tab in the direction of the arrow, then rotate the lever in the direction of the arrow and remove connector A-Mazda3



      Click image to see an enlarged view

      Fig. On connector B, rotate the lever in the direction of the arrow and remove connector B-Mazda3



      Click image to see an enlarged view

      Fig. Turn the screws counterclockwise to remove the PJB-Mazda3



      Click image to see an enlarged view

      Fig. Remove the PJB as shown-Mazda3

    10.  

  42.  
  43. Remove the car navigation unit.
  44.  
  45. Remove the lower panel as follows:
    1. Detach the hood release lever from the lower panel.
    2.  
    3. Remove the lever on 5 door models.
    4.  
    5. Remove the hood latch.
    6.  
    7. Remove the hood latch switch connector.
    8.  
    9. Pull the hood release lever. While pushing the tab in the direction of the arrow using a tape-wrapped, small flathead screwdriver, detach it from the lower panel.
    10.  
    11. Remove the hood release cable.
      CAUTION
      Be careful not to damage the hood release cable when removing the hood release lever with the flathead screwdriver.

    12.  
    13. Pull the hood release lever outward, then remove it from the lower panel.
    14.  
    15. Remove the front scuff plate.
    16.  
    17. Remove the front side trim.
    18.  
    19. Remove the screw.
    20.  
    21. Pull the lower panel outward, and detach clips A and tab.
    22.  
    23. Disconnect the panel light control switch connector and the headlight leveling switch connector.
    24.  
    25. Remove the lower panel.
    26.  

  46.  
  47. Remove the column cover as follows:
    1. Detach the fit of the upper column cover from the meter hood rubber.
    2.  
    3. Remove the upper column cover.
    4.  
    5. Remove the ignition key illumination.
    6.  
    7. Remove the screws.
    8.  
    9. Remove the lower column cover.
    10.  

  48.  
  49. 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 shaft-Mazda3

    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 steering angle sensor connector, if equipped with a steering angle sensor.
    22.  
    23. Remove the screw.
    24.  
    25. Remove the clock spring.

      Click image to see an enlarged view

      Fig. Exploded view of clock spring assembly-Mazda3



      Click image to see an enlarged view

      Fig. Remove the steering angle sensor by detaching the tabs at the four locations shown-Mazda3

    26.  
    27. Remove the steering angle sensor by detaching the tabs at the four locations shown in the figure and remove the steering angle sensor.
    28.  
    29. Remove the combination switch.
    30.  
    31. Remove the dust cover.
    32.  
    33. Remove the steering shaft.
    34.  

  50.  
  51. Remove the A-pillar trim shaft as follows:
    1. Partially peel back the seaming welt.
    2.  
    3. Detach clips A using a fastener remover.
    4.  
    5. Pull the A-pillar trim and detach clip B (1).
    6.  
    7. Pull the A-pillar trim upward and remove clip B from the A-pillar trim (2).
    8.  
    9. Pull clip B out and rotate it 45 degrees.

      Click image to see an enlarged view

      Fig. Exploded view of the A-pillar trim-Mazda3



      Click image to see an enlarged view

      Fig. Pull clip B out and rotate it 45 degrees to remove the A-pillar trim-Mazda3

    10.  
    11. Remove clip B from the grommet by pulling it upward.
    12.  

  52.  
  53. Remove the center panel module as follows:

    Click image to see an enlarged view

    Fig. Exploded view of the center panel module-Mazda3



    Click image to see an enlarged view

    Fig. Pull the center panel module outward, detach clip A from the dashboard, and then remove the center panel module-Mazda3

    1. Remove the screw and connector.
    2.  
    3. Remove the antenna feeder and the center panel module. Pull the center panel module outward, detach clip A from the dashboard, and then remove the center panel module.
    4.  

  54.  
  55. Remove the wiper arm and blade.
  56.  
  57. Remove the cowl grille.
  58.  
  59. Remove the cowl panel.
  60.  
  61. Remove the wiper motor bolts.
  62.  
  63. Move the wiper motor in the direction of the arrow, remove the securing rubber from the stud pin (for connecting the motor securing rubber), and then remove the windshield wiper motor.
  64.  
  65. Disconnect the windshield wiper motor connector.

    Click image to see an enlarged view

    Fig. Exploded view of the wiper motor mounting-Mazda3

  66.  
  67. Remove the A/C unit installation nut from the engine compartment, then remove the A/C unit.
  68.  
  69. Remove the rear heat duct.
  70.  
  71. Disconnect the drain hose connected to the A/C unit.
  72.  
  73. Remove the nuts and bolts for installing the dashboard to the body.
  74.  
  75. Remove the climate control unit.
  76.  
  77. Remove the LCD unit.
    CAUTION
    Handling the air bag module improperly can accidentally deploy the air bag module, which may seriously injure you. Due to the adoption of 2-step deployment control in the passenger-side air bag module, depending on the impact force, it is possible that inflator No.2 might not deploy. In such cases, before disposing of the air bag module, make sure to follow the inflator deployment procedures and verify complete deployment of inflators No.1 and 2.

  78.  
  79. Turn the ignition switch to the LOCK position.
  80.  
  81. Remove the dashboard garnish.
  82.  
  83. Remove the bolt, the passenger side air bag module, the nut and bracket.
  84.  
  85. Remove the heater case and duct.
  86.  
  87. Remove the power MOS FET connector.
  88.  
  89. Remove the evaporator temperature sensor connector.
  90.  
  91. Remove the air intake actuator connector.
  92.  
  93. Remove the air mix actuator connector.
  94.  
  95. Remove the airflow mode actuator connector.
  96.  
  97. Remove the resistor connector on models with manual air conditioner system.
  98.  
  99. Remove the blower motor connector.
  100.  
  101. Remove the upper and lower dashboard brackets.
  102.  
  103. Remove the cap and bolt.
  104.  
  105. Remove the dashboard.

    Click image to see an enlarged view

    Fig. Exploded view of the dashboard mounting-Mazda3

  106.  

To install:

 
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