1994 MAZDA MX-5 Workshop Manual

AIR CONDITIONER u REFRIGERANT LINES On-vehicle Inspection Check for leakage at the connections by using a gas leak tester. Repair or replace as necessary. b Replacement 1. Discharge the refrigerant system. 2. Replace the faulty pipe or hose. Immediately plug any open fittings to keep moisture out of the system. 3. Evacuate, charge, and test the refrigerant system. (Refer to page U-25) N.m (kgf m, fvlbf) Gartner Banana

u AIR CONDITIONER CONDENSER FAN Removal / Installation 1. Disconnect the negative battery cable. 2. Disconnect the cooling fan and condenser fan connector. 3. Remove the bolts. 4. Remove in the order shown in the figure. 5. Install in the reverse order of removal. 1. Cooling fan 2. Condenser fan Inspection 1. Disconnect the condenser fan connector. 2. Verify that the condenser fan motor runs when connect- ing battery positive voltage to terminal A and grounding terminal B. B+: Battery positive voltage u 45UOUX-082 U-36 Motor operation Yes Connection B+ A GND B Gartner Banana

AIR CONDITIONER REFRIGERANT PRESSURE SWITCH OPERATION 206 {2.1,30) 3,140 (32.0, 455) OFF ON n 230 {2.3,33) 2,550 (26.0,370) A/C RELAY Inspection 1. Remove the relay. 2. Apply battery positive voltage and check for continuity between terminals of the relay. B+: Battery positive voltage 3. If not as specified, replace the relay. CONDENSER FAN RELAY lnspection 1. Remove the relay. 2. Apply battery positive voltage and check for continuity between terminals of the relay. B+: Battery positive voltage 1 2 O--(): Continuity 3. If not as specified, replace the relay. 0 B+ 1 2 REFRIGERANT PRESSURE SWITCH lnspection If problems occur in the refrigerant system that cause ab- normally high pressure or abnormally low pressure, the pressure switch will cut power to the magnetic clutch to protect the mechanical components. If the pressure re- covers to within normal operating range, the power will be restored. These operating values are shown in the figure. kPa (kgf/cm2, psi) 35UOUX-020 1. Connect a manifold gauge set to the charging valve. 2. Verify that the high-pressure-side pressure is 230-2,550 kPa (2.3-26.0 kgf/cm2, 33-370 psi). 3. Disconnect the refrigerant pressure switch connector and check for continuity between the switch terminals. 4. If there is no continuity, replace the refrigerant pressure switch. 45UOUX-085 0 GND 0 B+ 0 0 GND 0 0 0 0 3 Gartner Banana

u AIR CONDITIONER A/C COMPRESSOR Removal / Installation 1. Raise the front of the vehicle at least 300 mm (11.8 In) and support it on safety stands. 2. Discharge the refrigerant system. i~ 3. Remove the splash shield and air guide. 4. Remove in the order shown in the figure. Immediately plug and open fittings to keep moisture out of the system. 5. Install in the reverse order of removal. Apply clean compressor oil to the O-rings before connecting the fittings; do not apply compressor oil to the fitting nuts. . 6. Adjust the belt tension. (Refer to page U-46.) 7. Install the air guide and splash shield. 8. Charge the refrigerant system. (Refer to page U-25.) 45uoux-086 i/ 1. Flexible hose 3. Magnetic clutch 2. AIC compressor Disassembly / Assembly . . . . . . page U-39 Disassembly / Assembly . . . . . . page U-41 Gartner Banana

AIR CONDITIONER u Disassembly l Assembly Magnetic clutch 1. Hold the clutch with the SST and remove the shaft bolt. 2. Remove the pressure plate with the SST. 3. Remove the shims. SNAP-RING PLIERS PLASTIC HAMMER 4. Remove the snap ring. 5. Remove the rotor by tapping it with a plastic hammer. Gartner Banana

u AIR CONDITIONER 6. Disconnect the stator wires from the compressor hous- ing. 7. Remove the snap ring and the stator. 8. Assemble in the reverse order of disassembly. Adjust the clearance between the pressure plate and the rotor by inserting the proper shims. Standard clearance: 0.4--0.6 mm (0.016-0.024 in) - Part No. KA10 61 L21 Thickness 0.1 Omm (0.004 in} KAlO 61 L22 KAIO 61 L23 0.30mm I0.012 in} 0.50mm 10.020 in} Gartner Banana

AIR CONDITIONER u A/C compressor housing @ REPLACE 45UOUX4 1. Discharge valve body 4. Front housing 2. Discharge valve plate 5. Shaft seal plate 3. Discharge valve 6. Shaft seal 7. Rear housing 8. Compressor body 1. Measuring of compressor oil amount Measure the amount of the compressor oil which is in the A/C compressor. 2. Removal of discharge valve body (1) Remove the discharge valve body installation through bolts. Gartner Banana

u AIR CONDITIONER PIN (2) Remove the discharge valve installation bolts and discharge valve body. 3. Removal of discharge valve Remove the bolts, discharge valve plate and discharge valve. 4. Removal of front and rear housings (1) Remove the through bolts and front housing. (2) Remove the rear housing. (3) Remove the pin and gaskets. Gartner Banana