Mazda MPV 1999-06

Removal & Installation

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1998-00 MPV



Front System
  1. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the battery, wait for more than 1 minute for the air bag system to deplete its stored energy.

  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Disconnect the heater hoses from the heater core.
  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 performing the following procedure:
    1. Place the wheel in the straight-ahead position and turn the ignition switch to LOCK.
    2.  
    3. Remove the lower steering column cover.
    4.  
    5. Disconnect the clock spring connector.
    6.  
    7. Remove the steering wheel-to-SAS module bolts.
    8.  
    9. Carefully, lift the SAS module from the steering wheel.
      CAUTION
      Place the SAS in a safe place with the module facing upward.

    10.  
    11. Remove the steering wheel-to-column nut.
    12.  
    13. Using a steering wheel puller, press the steering wheel from the steering column.
    14.  

  10.  
  11. At the passenger-s side, remove the SAS module by performing the following procedure:
    1. Remove the glove compartment by sliding it to the left; then, pull the right side forward to remove the stopper and the pin, then, move it to the right to remove it.
    2.  
    3. Remove the SAS module-to-dash bolts.
    4.  
    5. Carefully, lift the SAS module and disconnect the electrical connector.
      CAUTION
      Place the SAS in a safe place with the module facing upward.

    6.  

  12.  
  13. Remove the instrument panel by performing the following procedure:
    1. Remove the A-pillar trim from both sides.
    2.  
    3. Remove the front side trim and the side panel trim.
    4.  
    5. Remove the hood release handle and the lower panel.
    6.  
    7. Remove the meter hood and the instrument cluster.
    8.  
    9. Remove the steering column-to-instrument panel bolts and lower the steering column.
    10.  
    11. Disconnect the electrical connectors from the blower motor and the heater housing.
    12.  
    13. Remove the instrument panel hole cover and the instrument panel-to-chassis bolts.
    14.  
    15. Disconnect the electrical connectors.
    16.  
    17. Using an assistant, carefully remove the instrument panel.
    18.  

  14.  
  15. Remove the heater housing-to-chassis nuts.
  16.  
  17. Remove the heater housing-to-air conditioning housing fastener and seal plate.
  18.  
  19. Remove the heater housing.
  20.  
  21. Disassemble 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-Mazda MPV



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Exploded view of the steering column and related components-Mazda MPV



    Click image to see an enlarged view

    Fig. View of the instrument panel and related components-Mazda MPV



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater housing and related components-Mazda MPV

  22.  

To install:

  1. Install the heater core and assemble the heater housing.
  2.  
  3. Install the heater housing.
  4.  
  5. Install the heater housing-to-air conditioning housing seal plate and fastener.
  6.  
  7. Install the heater housing-to-chassis nuts.
  8.  
  9. Install the instrument panel by performing the following procedure:
    1. Using an assistant, carefully, install the instrument panel.
    2.  
    3. Connect the electrical connectors.
    4.  
    5. Install the instrument panel-to-chassis bolts and the instrument panel hole cover.
    6.  
    7. Connect the electrical connectors to the blower motor and the heater housing.
    8.  
    9. Install the steering column and the steering column-to-instrument panel bolts. Torque the bolts to 12-16 ft. lbs. (16-22 Nm).
    10.  
    11. Install the instrument cluster and the meter hood.
    12.  
    13. Install the hood release handle and the lower panel.
    14.  
    15. Install the front side trim and the side panel trim.
    16.  
    17. Install the A-pillar trim to both sides.
    18.  

  10.  
  11. At the passenger-s side, install the SAS module by performing the following procedure:
    1. Carefully, install the SAS module and connect the electrical connector.
    2.  
    3. Install the SAS module-to-dash bolts. Torque the bolts to 12-16 ft. lbs. (16-22 Nm).
    4.  
    5. Install the glove compartment by sliding it to the right; then, push the right side rearward to install the stopper and the pin, then, move it to the right.
    6.  

  12.  
  13. At the driver-s side, install the SAS module and the steering wheel by performing the following procedure:
    1. Install the steering wheel and the steering wheel-to-column nut. Torque the steering wheel nut to 29-36 ft. lbs. (40-49 Nm).
    2.  
    3. Carefully, install the SAS module to the steering wheel.
    4.  
    5. Install the steering wheel-to-SAS module bolts. Torque the bolts to 70-104 inch lbs. (7.9-11.7 Nm).
    6.  
    7. Connect the clock spring connector.
    8.  
    9. Install the lower steering column cover.
    10.  

  14.  
  15. Connect the heater hoses to the heater core.
  16.  
  17. Refill the cooling system.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  22.  

Rear Auxiliary System
  1. Disconnect the negative battery cable.
  2.  
  3. Set the rear heater control knob to the WARM position to open the water valve.
  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Remove the driver-s seat.
  8.  
  9. Disconnect the heater hoses.
  10.  
  11. Disconnect the rear heater unit wire connector.
  12.  
  13. Remove the rear heater unit attaching bolts and remove the assembly.
  14.  
  15. Separate the rear heater unit attaching bolts and remove the heater core.

    Click image to see an enlarged view

    Fig. View of the rear auxiliary heater assembly and related components-Mazda MPV



    Click image to see an enlarged view

    Fig. Exploded view of the rear auxiliary heater unit-Mazda MPV

  16.  

To install:

  1. Install the heater core and assemble the rear heater unit.
  2.  
  3. Install the assembly and the rear heater unit.
  4.  
  5. Connect the rear heater unit wire connector.
  6.  
  7. Connect the heater hoses to the heater core.
  8.  
  9. Install the driver-s seat.
  10.  
  11. Refill the cooling system.
  12.  
  13. Connect the negative battery cable.
  14.  

Front Heater Core



  1. Disconnect the negative battery cable.
  2.  


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

  1. Drain the cooling system into a clean container for reuse.
  2.  
  3. Disconnect the heater hoses from the heater core.
  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 performing the following procedure:
    1. Place the wheel in the straight-ahead position and turn the ignition switch to LOCK.
    2.  
    3. Remove the lower steering column cover.
    4.  
    5. Disconnect the clock spring connector.
    6.  
    7. Remove the steering wheel-to-SAS module bolts.
    8.  
    9. Carefully, lift the SAS module from the steering wheel.
    10.  

  8.  


CAUTION
Place the SAS in a safe place with the module facing upward.

  1. Remove the steering wheel-to-column nut.
  2.  
  3. Using a steering wheel puller, press the steering wheel from the steering column.
  4.  

  1. At the passenger-s side, remove the SAS module by performing the following procedure:
    1. Remove the glove compartment by sliding it to the left; then, pull the right side forward to remove the stopper and the pin, then, move it to the right to remove it.
    2.  
    3. Remove the SAS module-to-dash bolts.
    4.  
    5. Carefully, lift the SAS module and disconnect the electrical connector.
    6.  

  2.  


CAUTION
Place the SAS in a safe place with the module facing upward.

  1. Remove the instrument panel by performing the following procedure:
    1. Remove the A-pillar trim from both sides.
    2.  
    3. Remove the front side trim and the side panel trim.
    4.  
    5. Remove the hood release handle and the lower panel.
    6.  
    7. Remove the meter hood and the instrument cluster.
    8.  
    9. Remove the steering column-to-instrument panel bolts and lower the steering column.
    10.  
    11. Disconnect the electrical connectors from the blower motor and the heater housing.
    12.  
    13. Remove the instrument panel hole cover and the instrument panel-to-chassis bolts.
    14.  
    15. Disconnect the electrical connectors.
    16.  
    17. Using an assistant, carefully remove the instrument panel.
    18.  

  2.  
  3. Remove the heater housing-to-chassis nuts.
  4.  
  5. Remove the heater housing-to-air conditioning housing fastener and seal plate.
  6.  
  7. Remove the heater housing.
  8.  
  9. Disassemble the heater housing and remove the heater core.
  10.  


    Click image to see an enlarged view

    Fig. Exploded view of the steering wheel and SAS module



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Exploded view of the steering column and related components



    Click image to see an enlarged view

    Fig. View of the instrument panel and related components



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater housing and related components


To install:

  1. Install the heater core and assemble the heater housing.
  2.  
  3. Install the heater housing.
  4.  
  5. Install the heater housing-to-air conditioning housing seal plate and fastener.
  6.  
  7. Install the heater housing-to-chassis nuts.
  8.  
  9. Install the instrument panel by performing the following procedure:
    1. Using an assistant, carefully, install the instrument panel.
    2.  
    3. Connect the electrical connectors.
    4.  
    5. Install the instrument panel-to-chassis bolts and the instrument panel hole cover.
    6.  
    7. Connect the electrical connectors to the blower motor and the heater housing.
    8.  
    9. Install the steering column and the steering column-to-instrument panel bolts. Torque the bolts to 12-16 ft. lbs. (16-22 Nm).
    10.  
    11. Install the instrument cluster and the meter hood.
    12.  
    13. Install the hood release handle and the lower panel.
    14.  
    15. Install the front side trim and the side panel trim.
    16.  
    17. Install the A-pillar trim to both sides.
    18.  

  10.  
  11. At the passenger-s side, install the SAS module by performing the following procedure:
    1. Carefully, install the SAS module and connect the electrical connector.
    2.  
    3. Install the SAS module-to-dash bolts. Torque the bolts to 12-16 ft. lbs. (16-22 Nm).
    4.  
    5. Install the glove compartment by sliding it to the right; then, push the right side rearward to install the stopper and the pin, then, move it to the right.
    6.  

  12.  
  13. At the driver-s side, install the SAS module and the steering wheel by performing the following procedure:
    1. Install the steering wheel and the steering wheel-to-column nut. Torque the steering wheel nut to 29-36 ft. lbs. (40-49 Nm).
    2.  
    3. Carefully, install the SAS module to the steering wheel.
    4.  
    5. Install the steering wheel-to-SAS module bolts. Torque the bolts to 70-104 inch lbs. (7.9-11.7 Nm).
    6.  
    7. Connect the clock spring connector.
    8.  
    9. Install the lower steering column cover.
    10.  

  14.  
  15. Connect the heater hoses to the heater core.
  16.  
  17. Refill the cooling system.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  22.  

Front System



  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 air bag system 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.
    WARNING
    If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.

  8.  
  9. Remove the dashboard as follows:
    1. Bend the glove compartment door stoppers inward, then remove.
    2.  
    3. Pull the glove compartment toward you while pushing it downward, then remove the clip.
    4.  
    5. Remove by sliding the glove compartment toward the driver-s side door.
    6.  
    7. Turn the ignition switch to LOCK position.
    8.  
    9. Disengage the wiring connector from the passenger-side air bag module (if equipped with the Standard Deployment Control System), or wiring connector A from the air bag module (if equipped with the Two-Stage Deployment Control System).
    10.  
    11. Remove the air bag module mounting bolts from under the air bag module.
    12.  
    13. If equipped with the Two-Stage Deployment Control System, lift up the air bag module and disengage wiring connector B.
    14.  
    15. Remove the passenger-side air bag module from the vehicle.
      CAUTION
      Place air bag modules in a safe place with the module always facing upward.

    16.  
    17. Pull down the adjusting lever of the tilt steering wheel and push the steering wheel down.
    18.  
    19. Remove the meter hood.
    20.  
    21. Pull down the selector lever to the D range position.
    22.  
    23. Remove the instrument cluster mounting screws and disconnect the electrical connectors, then remove the cluster from the vehicle.
      WARNING
      When removing the instrument cluster, in order to prevent damage to the lens, cover the steering shaft with a cloth.

    24.  
    25. Remove the console lower cover and remove the dashboard lower panel.
    26.  
    27. Place the steering wheel in the straight-ahead position and turn the ignition switch to the LOCK position.
    28.  
    29. Remove the steering wheel-to-air bag module bolts.
    30.  
    31. Disconnect the clock spring connector(s).
    32.  
    33. Carefully, lift the air bag module from the steering wheel.
    34.  
    35. Remove the steering wheel-to-column nut and, using a steering wheel puller, press the steering wheel from the steering column.
    36.  
    37. Remove the steering column cover.
    38.  
    39. Remove the clock spring assembly.
    40.  
    41. Remove the combination switch.
    42.  
    43. Remove the clip and disconnect the selector cable from the selector lever.
    44.  
    45. Remove the selector lever.
    46.  
    47. Remove the column lower panel.
    48.  
    49. Remove the steering column-to-instrument panel bolts and lower the steering column.
    50.  
    51. Turn the seaming welt over at the right and left A-pillar trim.
    52.  
    53. Disengage the clips in the top portion of the A-pillar trim.
    54.  
    55. Pull the A-pillar trim upward, then disengage the bottom and lower hooks, then remove the right and left A-pillar trim.
    56.  
    57. Remove each side panel.
    58.  
    59. Remove the front scuff plates.
    60.  
    61. Turn the seaming welt over.
    62.  
    63. Pull the front side trim toward you, then disengage clip and pin from the body, and remove the right and left front side trim.
    64.  
    65. Disconnect the antenna plug.
    66.  
    67. For vehicles equipped with the wire-type climate control unit, disconnect the wires for the front A/C unit and disconnect the air mix and airflow mode wires from each wire clamp and link.
    68.  
    69. After removing the screws, pull the front climate control unit out and disconnect the connectors, then remove the front climate control unit.
    70.  
    71. Disconnect any remaining electrical connectors to the dashboard and/or front A/C unit.
    72.  
    73. Remove the dashboard mounting bolts.
      WARNING
      Removing the dashboard without supporting it can be dangerous. The dashboard may fall and injure you. Always perform these procedure together with at least another person.

    74.  
    75. Disconnect the thermosensor electrical connector from the front A/C unit.
    76.  
    77. Incline the dashboard slowly forward, then lift it while it is inclined forward and remove from vehicle through the passenger-side front door.
    78.  

  10.  
  11. Disconnect the heater hoses from the heater core.
  12.  
  13. Disconnect the cooler pipe and air duct from the front A/C unit.
  14.  
  15. Remove the mounting fasteners and remove the front A/C unit housing from the vehicle.
  16.  
  17. Disassemble the heater housing and remove the heater core.

    Click image to see an enlarged view

    Fig. Exploded view of the steering wheel and air bag module-standard deployment control system shown



    Click image to see an enlarged view

    Fig. Exploded view of the passenger-side air bag module-Two-step deployment control system shown



    Click image to see an enlarged view

    Fig. Exploded view of the steering column and related components



    Click image to see an enlarged view

    Fig. View of the instrument panel and related components



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, front A/C unit housing and related components



    Click image to see an enlarged view

    Fig. Exploded view of the front and rear HVAC system

  18.  

To install:

  1. Install the heater core and assemble the heater housing.
  2.  
  3. Install the heater housing and tighten the mounting fasteners.
  4.  
  5. Connect the cooler pipe and air duct to the front A/C unit.
  6.  
  7. Connect the heater hoses to the heater core.
  8.  
  9. Install the instrument panel by performing the following procedure:
    1. Using an assistant, carefully, install the instrument panel.
    2.  
    3. Connect the thermosensor electrical connector to the front A/C unit.
    4.  
    5. Connect any remaining electrical connectors to the dashboard and/or front A/C unit.
    6.  
    7. Install the instrument panel mounting bolts.
    8.  
    9. Install the front climate control unit into position and engage the connectors.
    10.  
    11. For vehicles equipped with the wire-type climate control unit, connect the wires to the front A/C unit and connect the air mix and airflow mode wires to each wire clamp and link.
    12.  
    13. Connect the antenna plug.
    14.  
    15. Install the right and left front side trim.
    16.  
    17. Install the right and left side panels.
    18.  
    19. Install the right and left A-pillar trim.
    20.  
    21. Install the steering column and the steering column-to-instrument panel bolts. Torque the bolts to 12-16 ft. lbs. (16-22 Nm).
    22.  
    23. Install the column lower panel.
    24.  
    25. Install the selector lever.
    26.  
    27. Install the combination switch.
    28.  
    29. Install the clock spring assembly.
    30.  
    31. Install the steering column cover.
    32.  
    33. Install the steering wheel and the steering wheel-to-column nut. Torque the steering wheel nut to 29-36 ft. lbs. (40-49 Nm).
    34.  
    35. Carefully, install the air bag module to the steering wheel.
    36.  
    37. Connect the clock spring connector(s).
    38.  
    39. Install the steering wheel-to-air bag module bolts. Torque the bolts to 79-112 inch lbs. (8.9-12.7 Nm).
    40.  
    41. Install the console lower cover and dashboard lower panel.
    42.  
    43. Install the instrument cluster and the meter hood.
    44.  
    45. Carefully, install the passenger-side air bag module and connect the electrical connector(s).
    46.  
    47. Install the passenger-side air bag module mounting bolts. Torque the bolts to 61-85 inch lbs. (7-9 Nm).
    48.  
    49. Install the glove compartment by sliding it to the right; then, push it downward to install the clip and bend the door stoppers inward to engage.
    50.  

  10.  
  11. Connect the heater hoses to the heater core.
  12.  
  13. Refill the cooling system.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Recharge the air conditioning system.
  18.  
  19. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  20.  

Rear Auxiliary System



  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Discharge and recover the air conditioning system refrigerant.
  6.  
  7. Remove the right rear side trim as follows:
    1. Turn the weatherstrip over (liftgate side and sliding door side).
    2.  
    3. Remove the mat set end plate.
    4.  
    5. Remove the rear scuff plate.
    6.  
    7. Pull the cup holder upward, then disengage clips A and pin B from the right rear side trim, and remove the cup holder.
    8.  
    9. Remove the bolts and fastener.
    10.  
    11. Pull the rear side trim toward you, then disengage clips C, pin D, tabs E and F from the body.
    12.  
    13. Disconnect the rear climate control unit connectors and rear tweeter connectors (if equipped).
    14.  
    15. Remove the right rear side trim.
      WARNING
      If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.

    16.  

  8.  
  9. Disconnect the rear heater hose No. 1.
  10.  
  11. Disconnect the rear heater hose No. 2.
  12.  
  13. Disconnect the rear cooler pipe No. 2.
  14.  
  15. Disconnect the rear A/C unit wire connectors.
  16.  
  17. Remove the rear A/C unit attaching bolts and remove the assembly.
  18.  
  19. Separate the rear A/C unit attaching bolts and remove the heater core.

    Click image to see an enlarged view

    Fig. Removal of right rear side trim cup holder assembly-Mazda MPV



    Click image to see an enlarged view

    Fig. Exploded view of the right rear side trim-Mazda MPV



    Click image to see an enlarged view

    Fig. Exploded view of the rear auxiliary A/C unit-Mazda MPV

  20.  

To install:

  1. Install the heater core and assemble the rear A/C unit.
  2.  
  3. Install the assembly into the vehicle.
  4.  
  5. Connect the rear A/C unit wire connectors.
  6.  
  7. Connect the heater hoses and rear cooler pipe to the assembly.
  8.  
  9. Install the right rear side trim.
  10.  
  11. Refill the cooling system.
  12.  
  13. Recharge the air conditioning system.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Run the engine to normal operating temperatures; then, check the rear climate control operation and check for leaks.
  18.  

 
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