Protege 1999-2000

Removal & Installation

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  1. Disconnect the negative battery cable.
  2.  
  3. Discharge the refrigerant from the system.
  4.  
  5. Remove the passenger-side lower panel.
  6.  
  7. Remove the glove compartment and glove compartment cover.
    CAUTION
    If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.

  8.  
  9. Disconnect cooler pipe No.3 and cooler hose (LO).
  10.  
  11. Remove the two connectors (1) and remove the cooling unit (2) (evaporator housing).
    CAUTION
    Do not allow compressor oil to spill.



    Click image to see an enlarged view

    Fig. Showing the cooling unit (evaporator housing) removal

  12.  
  13. Disassemble the cooling unit, following the numerical sequence given in the figure.

    Click image to see an enlarged view

    Fig. Disassemble the cooling unit, following the numerical sequence given in the figure.

  14.  

<To install:>

  1. Reassemble the cooling unit components. Follow the numerical sequence in reverse.
    NOTE
    If installing a new evaporator core, add 1.0 oz. of compressor oil during installation.

  2.  
  3. Continue with reassembly, noting the following:
  4.  

A/C Amplifier Assembly Note



Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Assemble the evaporator temperature sensor as shown in the figure.

    Click image to see an enlarged view

    Fig. Assemble the evaporator temperature sensor as shown in the figure.

  2.  

Adhesive Sponge Rubber Assembly Note



Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Attach the adhesive sponge rubber so that the heat sensing tube is hidden.
  2.  

Evaporator Assembly Note



Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Verify that the dent caused by contact with the polyurethane protector and cooler case (1) in the shaded zone is 3 mm or less.

    Click image to see an enlarged view

    Fig. Verify that the dent caused by contact with the polyurethane protector and cooler case (1) in the shaded zone is 3 mm or less.

  2.  

Expansion Valve Assembly Note



Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Apply compressor oil to the O-rings and connect the joint.
  2.  
  3. Tighten the nut of the joint by hand.
  4.  
  5. Tighten the joint with the specified torque with a spanner and torque wrench.
  6.  
  7. Assemble the heat-sensing tube as shown in the figure.
  8.  
  9. Route the capillary tube as shown in the figure.
  10.  
  11. Verify that the capillary tube is not in the shaded zone

    Click image to see an enlarged view

    Fig. Route the capillary tube as shown in the figure and verify that the capillary tube is not in the shaded zone

  12.  

Insulator Assembly Note



Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Make the two insulators cross.
  2.  
  3. Attach the insulator so that the shaded zone of expansion valve is hidden.

    Click image to see an enlarged view

    Fig. Make the two insulators cross, then attach the insulator so that the shaded zone of expansion valve is hidden.

  4.  

Polyethylene Foam Assembly Note



Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Apply the adhesive to a range of 1.97 in. (50 mm) from the edge of polyethylene foam, and around the drain outlet. Apply the polyethylene foam to the cooler case.

    Click image to see an enlarged view

    Fig. Apply the adhesive to a range of 1.97 in. (50 mm) from the edge of polyethylene foam, and around the drain outlet. Apply the polyethylene foam to the cooler case.

  2.  

Sensor Clamp Assembly Note



Specific to:

Mazda Protege 1998-2003

Mazda Protege5 2002-2003

  1. Assemble the sensor clamp as shown in the figure.

    Click image to see an enlarged view

    Fig. Assemble the sensor clamp as shown in the figure.

  2.  

 
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