Mazda Trucks 1987-1993 Repair Guide

Control Cables

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REMOVAL & INSTALLATION



Pickup

Refer to Control Head procedure.

Navajo

See Figures 1 and 2



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Fig. Fig. 1: Control cable connections at the head and the air plenum



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Fig. Fig. 2: Control cable routing diagram

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the control assembly from the instrument panel.
  4.  
  5. Disengage the glove compartment door by squeezing the sides together and allowing the door to hang free.
  6.  
  7. Working through the glove compartment and/or control opening, remove the temperature and function cable jackets from their clips on top of the plenum by compressing the clip tangs and pulling the cables upward.
  8.  
  9. Reach through the glove compartment opening and disconnect the function and temperature cables from their separate cams. The cable ends are secured to the cams under a retention finger.
  10.  
  11. The cables are routed inside the instrument panel with 2 routing aids. Remove the cables from these devices. Reaching through the control opening, pull the cables upward out of the wiring shield cut-out. Reaching through the glove box opening, pull the cables out of the plastic clip up inside the instrument panel.
  12.  
  13. Pull the cables from the instrument panel through the control assembly opening.
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To install:
  1. Working through the glove compartment opening and the control opening in the instrument panel, feed the end of the cables to the cam area. Feed the cables in from the glove compartment opening, making sure the coiled end of the white function cable and the round hole diecast end of the temperature cable go in first.
  2.  
  3. Attach the coiled end of the function cable to the function cam, making sure the cable is routed under the cable hold-down feature on the cam assembly. The pigtail coil may be facing either up or down.
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  5. Attach the diecast end of the temperature cable to the temperature cam making sure the cable is routed under the cable hold-down feature on the cam assembly.
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  7. Route the control end of the cable through the instrument panel until the ends stick out of the control opening. It is not necessary to insert the cable into any routing devices previously used. The routing aids are only necessary when the entire instrument panel is removed and reinstalled.
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  9. Attach the function and temperature cables to the control. Install the control assembly in the instrument panel.
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  11. Adjust the cables in their clips on top of the plenum.
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Make sure the radio antenna cable does not become disengaged from its mounting and fall into the plenum cam area where it could cause an increase in control assembly operating effort or a faulty selection of system functions.

  1. Connect the negative battery cable and make a final check of the system for proper control cable operation.
  2.  

MPV

  1. Disconnect the negative battery cable. Remove the two lower side panels and the undercover. Remove the steering column cover, if required.
  2.  
  3. Remove the instrument cluster assembly. Remove the switch panel attaching nuts. Remove the switch panel.
  4.  
  5. Remove the attaching screws and remove the temperature control assembly. Remove the lower center panel.
  6.  
  7. Remove the attaching screws and remove the airflow mode control assembly. Disconnect the temperature control cable from the heater unit. Disconnect the rec/fresh cable and the airflow cable from the heater unit.
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  9. Install in the reverse order. Adjust the cables.
  10.  

ADJUSTMENT



Pickup

See Figures 3, 4 and 5



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Fig. Fig. 3: Airflow mode control cable adjustment



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Fig. Fig. 4: Temperature control cable adjustment



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Fig. Fig. 5: REC/FRESH selector control cable adjustment

  1. To adjust the airflow mode cable: Set the airflow mode control lever to the DEFROST position. Install the airflow mode cable with the shutter lever on the heater unit pushed fully forward. Attach the securing clip. Turn the blower switch to position 4 and make sure there are no air leaks from the center and floor outlets.
  2.  
  3. To adjust the temperature control cable: Set the temperature control lever to the COLD position. Install the temperature control cable with the shutter lever on the heater unit pushed fully upward. Attach the securing clip. Make sure the temperature control lever move fully from the COLD to HOT position.
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  5. To adjust the rec/fresh control cable: Set the rec/fresh selector lever to the RECIRCULATE position. Install the rec/fresh cable with the shutter lever on the blower unit pushed fully upward. Attach the securing clip. Make sure the rec/fresh selector move fully from the RECIRCULATE to the FRESH position.
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Navajo

To check the temperature cable adjustment, move the temperature control lever all the way to the left, then move it all the way to the right. At the extreme ends of lever travel, the door should be heard to firmly seat, indicated by a loud thumping sound, allowing either maximum or no air flow through the heater core. To check the function cable adjustment, see that the function lever will reach the detents at the far left and right of its travel. In addition, check that the air flow is correct when the function lever is moved through each detent provided in the control assembly. If cable adjustment is needed, proceed as follows:

  1. Disengage the glove compartment door by squeezing its sides together. Allow the door to hang free.
  2.  
  3. Working through the glove compartment opening, remove the cable jacket from the metal attaching clip on the top of the plenum by depressing the clip tab and pulling the cable out of the clip.
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The adjustable end should remain attached to the door cams.

  1. To adjust the temperature control cable, set the temperature lever at COOL and hold. With the cable end attached to the temperature door cam, push gently on the cable jacket to seat the blend door. Push until resistance is felt. Reinstall the cable to the clip by pushing the cable jacket into the clip from the top until it snaps in.
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  3. To adjust the function control cable, set the function selector lever in the DEFROST detent and hold. With the cable end attached to the function cam, pull on the cam jacket until cam travel stops. Reinstall the cable to the clip by pushing the cable jacket into the clip from the top until it snaps in place.
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  5. Install the glove compartment.
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  7. Run the system blower on HIGH and actuate the levers, checking for proper adjustment.
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MPV

  1. To adjust the temperature control cable: Set the temperature control lever to the MAX-HOT position. Install the cable and secure the attaching clip with the heater unit shutter lever all the way to the right. Make sure the temperature control lever moves easily from the HOT to COLD position.
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  3. To adjust the airflow cable: Set the airflow mode control lever to the DEFROST position. Install the cable and attaching clip with the heater unit shutter lever at its closest point. Make sure the control lever moves easily between the DEFROST and VENT positions.
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  5. To adjust the rec/fresh control cable: Set the rec/fresh lever to the RECIRCULATE position. Install the cable and attaching clip with the blower unit shutter lever at its closest point. Make sure the control lever moves easily from the RECIRCULATE to the FRESH position.
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