Mazda RX-8 2004-06

Removal & Installation

Print


CAUTION
Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components. Please refer to the precautions regarding the A/C system in this section.

  1. Disconnect the negative battery cable.
  2.  
  3. Discharge the refrigerant from the system, as outlined in this section.
  4.  
  5. Remove the fresh-air duct and air cleaner.
  6.  
  7. Remove the drive belt, as outlined in the Engine Mechanical Section.
    WARNING
    Do not allow the remaining compressor oil in the A/C compressor and pipes to spill

  8.  
  9. Remove the (HI) cooler hose and the (LO) cooler hose, noting the following:
    1. Disconnect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly, and then remove the connection bolt or nut.

      Click image to see an enlarged view

      Fig. Disconnect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly, and then remove the connection bolt or nut

    2.  
    3. For the quick joint type of pipes, install the SST (49 N061 0A0) to the arrow side of the clamp.

      Click image to see an enlarged view

      Fig. For the quick joint type of pipes, install the SST (49 N061 0A0) to the arrow side of the clamp

    4.  
    5. Then, push the SST (49 N061 0A0) with your thumb until it snaps into the clamp.
      WARNING
      Excessive force to the SST (49 N061 0A0) may damage the clamp. Be careful not to press too hard when inserting the SST (49 N061 0A0) into the clamp.



      Click image to see an enlarged view

      Fig. . . . then push the SST (49 N061 0A0) with your thumb until it snaps into the clamp,

    6.  

  10.  
  11. Finally, raise the stopper, and pull the SST (49 N061 0A0) from the piping.

    Click image to see an enlarged view

    Fig. . . . raise the stopper, and pull the SST (49 N061 0A0) from the piping

    1. Remove the SST (49 N061 0A0) from the clamp.
      WARNING
      Be careful not to bend the SST (49 N061 0A0) needle when removing the clamp. If the SST (49 N061 0A0) needle is bent, the clamp can not be opened.

    2.  

  12.  
  13. Detach the A/C compressor connector.
  14.  
  15. Remove the retainers and the A/C compressor.
    WARNING
    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. Exploded view of the (HI) cooler hose (1), (LO) cooler hose (2), A/C compressor connector (3) and A/C compressor (4)

  16.  

To install:


WARNING
Due to the high moisture-absorption characteristics of the compressor oil, it may absorb moisture if left over a long period of time thereby negatively affecting A/C operation. Drain the compressor oil and refill within 10 min. of each other.


NOTE
You must use DENSO OIL8 compressor oil. The compressor approximate sealed volume is 2.03 oz (60cc/60 ml).

  1. Install the compressor. You must make sure the oil level in the compressor is correct, as follows:
    1. Rotate new A/C compressor shaft six to eight revolutions while collecting refrigerant oil in a clean measuring device. Use this refrigerant oil to refill new compressor. Do not allow refrigerant oil to become contaminated.
    2.  
    3. Rotate old A/C compressor shaft six to eight revolutions while collecting refrigerant oil in a separate, clean measuring device.
    4.  
    5. Compare those oil amounts. The amount of the oil drained from the new A/C compressor should be greater than the old one.
    6.  
    7. Pour the same amount oil of drained from the old A/C compressor back into the new A/C compressor.

      Click image to see an enlarged view

      Fig. Pour the same amount oil of drained from the old A/C compressor back into the new A/C compressor

    8.  

  2.  
  3. Attach the compressor connector.
  4.  
  5. Install the (HI) and (LO) cooler hoses. When installing the cooler hoses:
    1. Apply compressor oil to the O-ring joints.
    2.  
    3. Tighten the piping joints.
    4.  
    5. For block joint type, temporarily tighten the joint bolt by hand. Connect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly, and then tighten the connection bolt or nut with a torque wrench.

      Click image to see an enlarged view

      Fig. Connect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly, and then tighten the connection bolt or nut with a torque wrench

    6.  

  6.  
  7. Install the remaining components in the reverse order of removal.
  8.  
  9. Charge the A/C system, as outlined in this section.
  10.  
  11. Perform the refrigerant system performance test, as outlined in this section.
  12.  

 
label.common.footer.alt.autozoneLogo