1994 MAZDA MX-5 Workshop Manual

HEATER u Disassembly I Assembly is assemble and assemble as shown in the figure. 1. Blower motor 2. Resistor 3. Air intake door Inspection Blower motor 1. Verify that the blower motor runs when connecting bat- tery positive voltage to terminal A and grounding termi- nal B. 2. If the blower motor does not run, replace it. Resistor 1. Check for continuity between the terminals of the resis- tor. 1 Terminals Continuity I I C-LO I Yes I I C-Me I Yes I I C- Mh I Yes I I C-Hi I Yes I 2. If not as specified, replace the resistor. U-19 Gartner Banana

u HEATER HEATER CONTROL UNIT Removal 1 Installation 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal. 1. Center console 2. Vent outlet 3. Center panel assembly 4. Heater control unit Adjustment . . . . . . . . . . . . . . . . . . page U-22 Gartner Banana

HEATER u Disassembly 1 Assembly 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of disassembly. 1. Air intake wire 5. Mode lever Adjustment .................. page U-22 6. Temperature-control lever 2. Airflow mode wire 7. Fan switch and ACS u Adjustment .................. page U-22 Inspection ................... page U-22 3. Air mix wire 8. Panel Adjustment .................. page U-22 9. Switch body 4. RECIFRESH lever Gartner Banana

u HEATER I_-K' AIR MIX WlRE -/ AIRFLOW MODE WlRE VENT bm -:JJ 45UOUX-04 AIR INTAKE WlRE / SHUTTER LEVER 45uoux-041 U-22 Inspection 1. Check for continuity between the terminals of the switch. Fan switch ACS Position I I I I I I I I OFF I I Terminal A~B~C~D~E~F~G~H I 1-1 I I I 1- 1- OFF First Second M: Continuity 0-0: Diode 2. If not as specified, replace the switch. Third 0 -0 0 Adjustment Air mix wire 1. Set the temperature-control lever to MAX HOT. 2. Connect and clamp the wire with the shutter lever on the heater unit all the way to the right. 3. Move the temperature-control lever to make sure the -, wire is securely attached and that it moves fully from HOT to COLD. Airflow mode wire 1. Set the mode lever to VENT. 2. Connect and clamp the wire with the shutter lever on the heater unit at its closest point. 3. Move the mode lever to make sure the wire is securely attached and that it moves fully from DEF to VENT. 0 RECIFRESH wire 1. Set the REC/FRESH lever to FRESH. 2. Connect and clamp the wire with the shutter lever on the blower unit at its closest point. 3. Move the RECJFRESH lever to make sure the wire is se- curely attached and that it moves fully from REC to FRESH. u 0 0-4 Gartner Banana

AIR CONDITIONER U AIR CONDITIONER PREPARATION i, SST I I c STRUCTURAL VIEW 00007-10331 Stopper, magnetic clutch 4992-02-020 Pressure plate remover For removal and installation of magnetic clutch For removal of pressure plate 1. Cooling unit 5. Condenser fan relay Removal I Installation ......... page U-30 Inspection ................... page U-37 Disassembly I Assembly ...... page U-31 6. AX: compressor 2. Condenser Removal I Installation ......... page U-38 Removal I Installation ......... page U-33 Disassembly I Assembly ...... page U-41 w 3. Receiver drier 7. Magnetic clutch Removal / Installation ......... page U-33 Disassembly / Assembly ...... page U-39 4. A/C relay Inspection ................... page U-37 Gartner Banana

u AIR CONDITIONER SERVICE WARNINGS Storing Refrigerant The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode, scattering u metal fragments and liquid refrigerant that can seri- ously injure you. Store the refrigerant at tempera- tures below 40°C (1 04°F). Handling Refrigerant Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostabite. When handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes, im- mediately wash them with clean water and consult a doctor. SERVICE CAUTIONS Compressor oil (ND-OILS) Do not spill compressor oil on the vehicle. A drop of compressor oil on the vehicle surface can eat away at the paint. If oil gets on the vehicle, wipe it off im- mediately. b PAG compressor oil (ND-OILS) has a higher mois- ture absorption efficiency than the previously used mineral oil. If moisture mixes with the compressor oil, the refrigerant system could be damaged. There- fore, install caps immediately after using the com- pressor oil or removing refrigerant system parts to prevent moisture absorption. Gartner Banana

AIR CONDITIONER u NIFOLD GAUGE CHARGING HOSE (HI) QUICK COUPLER REFRIGERANT SYSTEM SERVICE PROCEDURE Manifold Gauge Set Installation 1. Fully close the valves of the manifold gauge. 2. Connect charging hoses to the high and low-pressure- side joints of the manifold gauge set. 3. Connect quick couplers to the ends of the charging hoses. 4. Remove the caps from the charging valves of the high and low-pressure-side cooler pipes. 5. Connect the quick couplers to the charging valves of the cooler pipes. Charging 1. Install the manifold gauge set. 2. Connect the tap pin side of the charging hose to the air purge valve of the gauge set. 3. Connect the vacuum pump hose to the center joint of the gauge set. 4. Connect the vacuum pump hose to the vacuum pump. 5. Connect can puncture valves to 4-way joint. 6. Fully open the can puncture valves and connect service cans to the valves. Regular amount of refrigerant: 600 g (21.2 oz) 7. Fully close any can puncture valve that is not connected to a service can. 8. Connect the 4-way joint to the charging hose that is con- nected to the gauge set air purge valve. 9. Open all the valves of the manifold gauge set. 10. Start the vacuum pump and let it operate for 15 minutes. 11'. After 15 minutes, verify that the high and low-pressure- side readings of the manifold gauge set are at -1 01 kPa {-760 mmHg, -29.9 inHg}. Close each valve of the gauge set. 12. Stop the vacuum pump and wait for about 5 minutes. 13. After 5 minutes, check the low-pressure-side reading of the gauge set. If the reading changed, check for leaks and then repeat from step 9. If the reading has not changed, go to step 14. 14. Open the service cans by using the can puncture valves. 15. Open the low-pressure-side valve of the manifold gauge set and charge with refrigerant unit the low-pressure- side reading is at 100 kPa (1 kgf/cm2, 10 psi). 16. Close the low-pressure-side valve of the gauge set. Gartner Banana

u AIR CONDITIONER LEAK TESTER I LEAK TESTER I 17. Check for leaks by using a leak tester. If there are no leaks, go to step 18. If a leak is found at loose joint, tighten the joint and check for leaks again. If there is still a leak at the same joint, dis- 4 charge the refrigerant and then repair the joint. Repeat the charging procedure from step 9. If there are no leaks after tightening the joint, go to step 18. Warning Running the engine with the high-pressure-side valve open is dangerous. Pressure within the ser- vice cans will increase and the cans could ex- plode, scattering metal fragments and liquid refrigerant that can seriously injure you. There- fore, do not open the high-pressure-side valve while the engine is running. 18. Open the low-pressure-side valve of the manifold gauge set and charge with the regular amount of refrigerant. 19. Close the low-pressure-side valve of the manifold gauge set. 20. Check for leaks by using a leak tester. If there are no leaks, go to step 21. If a leak is found at loose joint, tighten the joint and check for leaks again. If there is still a leak at the same joint, dis- charge the refrigerant and then repair the joint. Repeat the charging procedure from step 9. If there are no leaks after tightening the joint, go to step 21. 21. Disconnect the high and low-pressure-side quick cou- plers from the charging valves that are connected to the high and low-pressure-side cooler pipes of the refriger- ant system. 22. Install the caps to the charging valves of the cooler pipes. Gartner Banana