A/C Core Removal/Installation

CAUTION:

To prevent system contamination, whenever the condenser core is replaced, also replace the receiver/drier.

NOTE:

If a condenser core leak is suspected, the condenser core must be leak tested before it is removed from the vehicle. See A/C EVAPORATOR/CONDENSER CORE - ON-VEHICLE LEAK TEST .

NOTE:

Replacement of the suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.

Recover the refrigerant. See A/C REFRIGERANT SYSTEM TESTS .
For vehicles with 2.3L or 4.0L engines, remove the air cleaner outlet tube and the engine air cleaner. See AIR CLEANER OUTLET PIPE REMOVAL/INSTALLATION - 2.3L or ENGINE AIR CLEANER REMOVAL/INSTALLATION - 4.0L .
Disconnect the condenser to evaporator line from the condenser core.
- Discard the O-ring seal.
  
  Fig 1: Disconnecting Condenser To Evaporator Line From Condenser Core - With Torque Specification
  Courtesy of MAZDA MOTORS CORP.
Disconnect the compressor manifold and tube assembly from the condenser core.
- Discard the O-ring seal.
  
  Fig 2: Disconnecting Compressor Manifold And Tube Assembly From Condenser Core - With Torque Specification
  Courtesy of MAZDA MOTORS CORP.
Remove the screws and tilt the radiator back.

Fig 3: Removing Screws - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Remove the pin-type retainers and remove the top seal.

Fig 4: Removing Pin-Type Retainers And Top Seal
Courtesy of MAZDA MOTORS CORP.
NOTE:
- It may be necessary to remove the radiator from the mounting saddles to provide clearance for the condenser core removal.
Remove the screws and the condenser core.

Fig 5: Removing Condenser Core Screws - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
To install, reverse the removal procedure.
- Lubricate the refrigerant system with the correct amount of clean refrigerant oil. See A/C REFRIGERANT OIL ADDITION .
- Install new O-ring seals lubricated with clean refrigerant oil.
Evacuate, leak test, and charge the refrigerant system. See A/C REFRIGERANT SYSTEM TESTS .