Mazda Protege 5. Manual - part 276

BASIC SYSTEM 

07–11–4

5. Disconnect cooler pipe No.3 and cooler hose 

(LO). (See 07–11–15 Refrigerant Lines Removal 
Note.) (See 07–11–16 Refrigerant Lines 
Installation Note.)

6. Remove in the order indicated in the table. Do not 

allow compressor oil to spill.

7. Install in the reverse order of removal.
8. Perform the refrigerant system performance test. 

(See 07–10–2 REFRIGERANT SYSTEM 
PERFORMANCE TEST.)

Cooling Unit Installation Note

1. When installing a new cooling unit (evaporator), add a supplemental amount of ATMOS GU10 compressor oil 

into the refrigeration cycle.

Supplemental amount (approximate quantity)

30 ml {30 cc, 1.0 fl oz}

End Of Sie

COOLING UNIT DISASSEMBLY/ASSEMBLY

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1. Disassemble in the order indicated in the table.

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.

1

Connector

2

Cooling unit
(See 07–11–4 Cooling Unit Installation Note)

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BASIC SYSTEM 

07–11–5

07–11

2. Assemble in the reverse order of disassembly.

Expansion Valve Assembly Note

1. Apply compressor oil to the O-rings and connect the joint.
2. Tighten the nut of the joint by hand.
3. Tighten the joint with the specified torque with a spanner and torque wrench.
4. Assemble the heat-sensing tube as shown in the figure.
5. Route the capillary tube as shown in the figure.

6. Verify that the capillary tube is not in the shaded 

zone

1

Resistor

2

Polyurethane foam

3

Polyurethane protector (1)

4

Polyurethane protector (2)

5

Cooler case (1)

6

Cooler case (2)

7

Polyethylene foam
(See 07–11–7 Polyethylene Foam Assembly Note)

8

Sensor clamp
(See 07–11–7 Sensor Clamp Assembly Note)

9

A/C amplifier
(See 07–11–6 A/C Amplifier Assembly Note)

10

Insulator
(See 07–11–6 Insulator Assembly Note)

11

Adhesive sponge rubber
(See 07–11–6 Adhesive Sponge Rubber Assembly 
Note)

12

Sponge rubber

13

Polyurethane protector (3)

14

Polyethylene protector

15

Polyurethane protector (4)

16

Evaporator
(See 07–11–6 Evaporator Assembly Note)

17

Expansion valve
(See 07–11–5 Expansion Valve Assembly Note)

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BASIC SYSTEM 

07–11–6

Evaporator Assembly Note

1. Verify that the dent caused by contact with the 

polyuretane protector and cooler case (1) in the 
shaded zone is 3 mm {0.12 in} or less.

Adhesive Sponge Rubber Assembly Note

1. Attach the adhesive sponge rubber so that the 

heat sensing tube is hidden.

Insulator Assembly Note

1. Make the two insulators cross.
2. Attach the insulator so that the shaded zone of 

expansion valve is hidden.

A/C Amplifier Assembly Note

1. Assemble the evaporator temperature sensor as 

shown in the figure.

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BASIC SYSTEM 

07–11–7

07–11

Sensor Clamp Assembly Note

1. Assemble the sensor clamp as shown in the 

figure.

Polyethylene Foam Assembly Note

1. Apply the adhesive to a range of 50 mm {1.97 in} 

from the edge of polyethylene foam, and around 
the drain outlet. Apply the polyethylene foam to 
the cooler case (2).

End Of Sie

EVAPORATOR INSPECTION

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1. Remove the cooling unit. (See 07–11–3 COOLING UNIT REMOVAL/INSTALLATION.)
2. Remove the evaporator from the cooling unit.
3. Inspect for cracks, damage, and oil leakage.

•

If any problems are found, replace the evaporator.

4. Inspect for bent fins.

•

If any are bent, use a flathead screwdriver to straighten them.

End Of Sie

HEATER UNIT REMOVAL/INSTALLATION

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1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See 01–12–3 ENGINE COOLANT REPLACEMENT.)
3. Remove the dashboard. (See 09–17–1 DASHBOARD REMOVAL/INSTALLATION.)
4. Remove the cooling unit. (See 07–11–3 COOLING UNIT REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.

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