Mazda Car 2005-06

Removal & Installation 3

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Air Mix Actuator



  1. Installation is the reverse of removal, please note 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-Mazda3



      Click image to see an enlarged view

      Fig. From the stopped position, turn the clock spring counterclockwise 2 3/4 turns-Mazda3



      Click image to see an enlarged view

      Fig. Align the marks on the clock spring-Mazda3

       
      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 in alphabetical order.

      Click image to see an enlarged view

      Fig. Tighten the steering shaft bolts in alphabetical order-Mazda3

    4.  
    5. Set the wheels in the straight-ahead position and install the steering wheel
      CAUTION
      When installing the center panel module, make sure that the wiring harness and antenna feeder are not caught between the unit and dashboard. If the wiring harness or the antenna feeder is caught between the unit and dashboard, it may cause malfunctions.

    6.  
    7. Select Cable for models with an manual transmission should be installed as follows:

      Make sure that the shift lever (transaxle side) is in neutral
       
      Push the safety lock, then unlock the lock piece of the select cable in the order shown in the illustration.
       
      Shift the sift lever to neutral.
       
      Lock the lock piece of the selector cable in the illustration.
       
      Shift the shift lever from neutral to other position, and make sure that there are no other components in that area to interfere with the lever.

      Click image to see an enlarged view

      Fig. Push the safety lock, then unlock the lock piece of the select cable in the order shown, on manual transmissions-Mazda3



      Click image to see an enlarged view

      Fig. Lock the lock piece of the selector cable, on manual transmissions-Mazda3

       

    8.  
    9. Selector lever for models with an automatic transmission should be installed as follows:

      Insert the location pin of selector lever component to the hole of the floor
       
      Tighten the selector lever component installation bolts to 7.8-10.8 Nm (69.5-95.4 in. lbs.).

      Click image to see an enlarged view

      Fig. Insert the location pin of selector lever component to the hole of the floor on models with an automatic transmission-Mazda3



      Click image to see an enlarged view

      Fig. Verify the selector cable is in this position on models with an automatic transmission-Mazda3



      Click image to see an enlarged view

      Fig. Lock the lock piece and safety lock of the selector cable in this order on models with an automatic transmission-Mazda3



      Click image to see an enlarged view

      Fig. Bending the selector cable in the manner shown in the illustration will damage the cable and it may become loose when shifted on models with an automatic transmission-Mazda3

       

    10.  
    11. Selector Cable for models with an automatic transmission should be installed as follows:
      CAUTION
      Bending the selector cable in the manner shown in the illustration will damage the cable and it may become loose when shifted. When installing the selector cable, hold it straight.


      NOTE
      Install the selector cable to the manual shaft cable with the clip side of the selector cable end facing the front of the vehicle.



      Install the selector cable to the selector lever securely.
       
      Install the selector cable to the bracket securely.
       



      Install the clip as shown in the illustration.
       



      Install the selector cable to the manual shaft lever in such a way that the selector cable does not bear a load.
       
      Confirm that the end of the manual shift lever projects from the end of the selector cable.

      Click image to see an enlarged view

      Fig. Install the selector cable to the manual shaft cable with the clip side of the selector cable end facing the front of the vehicle on models with an automatic transmission-Mazda3



      Click image to see an enlarged view

      Fig. Install the selector cable to the manual shaft lever in such a way that the selector cable does not bear a load on models with an automatic transmission-Mazda3

       
      Install the selector cable to the selector cable bracket securely.
       

    12.  
    13. Install the connector B as shown in the illustration.

      Click image to see an enlarged view

      Fig. Install the connector B as shown-Mazda3



      Click image to see an enlarged view

      Fig. After connecting connector A, rotate the lever in the direction of the arrow-Mazda3

    14.  
    15. After connecting connector A, rotate the lever in the direction of the arrow to install connector A.
    16.  
    17. Turn the ignition switch to the ON position.
    18.  
    19. Verify that the air bag system warning light goes out.
    20.  
    21. If the air bag system warning light does not operate normally, inspect of the system.
    22.  

  2.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the glove compartment.
  4.  
  5. Remove the air mix actuator connector and actuator.
  6.  

To install:

  1. Installation is the reverse of removal.
  2.  

  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.
  40.  
  41. Remove the theft control module bolt, connector and the module.
  42.  
  43. Disconnect the heater hose at the firewall.
  44.  
  45. 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-Mazda6 and Mazdaspeed6 models

  46.  
  47. Remove the heater core on Mazd6 models by removing or disconnecting the following:

    Duct
     
    Blower motor.
     
    A/C case 3 and case 4
     
    Harness
     
    Air intake actuator
     
    Air intake crank
     
    Air filter cover
     
    Air filter
     
    Resistor if equipped with a manual A/C system
     
    PMW unit if equipped with a fully automated A/C system
     
    Harness if equipped with a fully automated A/C system
     
    Air flow mode actuator
     
    Air flow mode bracket, main link, sub link and crank
     
    Air mix link and crank if equipped with a manual A/C system
     
    Air mix actuator, link and crank if equipped with a fully automated A/C system

    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

     

  48.  

To install:

 
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