AC Compressor — the pump that pressurizes the refrigerant
Condenser — the radiator-like unit in front of the engine radiator that cools the hot refrigerant gas
Receiver/Drier — a filter/dryer canister that removes moisture and debris (MUST be replaced whenever the system is opened to air)
O-rings — all seals at every refrigerant connection point (reusing old O-rings = guaranteed leaks)
Expansion valve (recommended, but requires evaporator access under the dashboard — consider having a shop do this part if you're replacing it)
Why Replace All At Once?
When an AC compressor fails, it often sends metal debris throughout the system. If you only replace the compressor, that debris will circulate and destroy the new one. Replacing the condenser and receiver/drier removes the main contamination points. Most compressor warranties also require replacement of the receiver/drier and O-rings.
SAFETY WARNINGS
Refrigerant: R-134a can cause frostbite on skin contact. When exposed to open flame or hot surfaces, it decomposes into toxic gases (phosgene). Always work in a well-ventilated area. Wear safety glasses and gloves.
Hot coolant: NEVER open the cooling system when the engine is hot. Pressurized coolant can spray and cause severe burns. Let the engine cool completely first.
Battery: Always disconnect the negative battery cable before working on AC components. The compressor clutch is electrically activated.
Vehicle support: If you jack up the car, ALWAYS use jack stands on solid frame points. Never work under a car supported only by a jack.
EPA Law: It is illegal to vent R-134a refrigerant into the atmosphere. Fines up to $44,539 per day per violation under the Clean Air Act. You must properly recover the refrigerant before opening any lines. See Section 3.5.
Key Specifications
Specification
Value
Refrigerant Type
R-134a
Refrigerant Charge Amount
480g (~16.9 oz) — verify on underhood sticker
Compressor Oil Type
PAG ISO 46 (FD46XG)
Total System Oil Capacity
120 ml (4.06 fl oz)
Drive Belt Type
Single serpentine belt with automatic tensioner (2.5L)
AC System Overview — Component LocationsAC System Component Details
Section 1 — Parts List
Order all parts before starting. Having everything on hand avoids leaving the system open to moisture while waiting for deliveries.
AC Compressor (2013 Mazda5 2.5L)HS18 type compressor — comes pre-oiledSearch Amazon
AC CondenserAluminum parallel-flow type; sits in front of radiatorSearch Amazon
Receiver/DrierMUST replace when system is opened. Contains desiccant that absorbs moisture.Search Amazon
Expansion Valve (Optional)Located at the evaporator under the dashboard — replacing it requires significant dash disassembly. Skip unless you suspect it's faulty, or have a shop do this part.Search Amazon
O-Ring Seal Kit (full AC system)Replace ALL o-rings at every connection. Never reuse old ones.Search Amazon
R-134a RefrigerantNeed 480g (~17 oz). Buy 2–3 cans of 12 oz each.Search Amazon
PAG 46 Compressor OilFD46XG compatible. For oil balancing procedure. Need at least 120ml.Search Amazon
Engine Coolant (FL22 type)~4L needed for top-up after draining radiator. Pre-mixed or concentrate+distilled water.Search Amazon
Serpentine Belt (optional — if worn)Good time to replace if cracked/glazed. 2013 Mazda5 2.5L.Search Amazon
Pro Tip: Many vendors sell complete AC kits that bundle the compressor, condenser, receiver/drier, expansion valve, and O-ring kit at a discount. Search for "2013 Mazda 5 AC kit" on Amazon or RockAuto.
Search AC Kits on Amazon
Section 2 — Tools Required
AC-Specific Tools
AC Manifold Gauge SetWith R-134a quick-connect couplers. Blue=low side, Red=high side, Yellow=center service hose.Search Amazon
AC Recovery/Recycling MachineRequired to legally recover R-134a before opening lines. Many units (like the VEVOR) also include a built-in vacuum pump for evacuation, so you may not need a separate one. See Section 3.5.Search Amazon
Vacuum Pump (1/4 HP or larger)Only needed if your recovery machine does NOT have a built-in vacuum pump. Used to evacuate air and moisture before charging.Search Amazon
Digital Kitchen/Postal ScaleFor weighing refrigerant precisely by gram. Must charge by weight, NOT pressure.Search Amazon
Electronic AC Leak DetectorSniffs for refrigerant leaks at connections after charging.Search Amazon
Spring Lock Coupling Disconnect Tool SetIf your lines use spring-lock fittings (push-to-connect type), you need these to release them.Search Amazon
Vehicle Lifting
Floor Jack (2+ ton)For raising the front of the car. The Mazda5 front jack point is the front crossmember.Search Amazon
Jack Stands (pair, 2+ ton)Place on the front pinch welds (reinforced seams along the underside of the car, behind each front wheel).Search Amazon
Wheel ChocksPlace behind rear wheels before jacking.Search Amazon
Breaker bar or long ratchet + 15mm or 19mm socket (for the serpentine belt tensioner)
Trim removal tools / plastic pry bars (for clips and push-pins)
Miscellaneous
Drain pans (2) — one for coolant, one for compressor oil
Caps/plugs for open refrigerant fittings (or clean rags + zip ties as temporary seals)
Clean measuring cup (for compressor oil transfer)
Paper towels / shop rags
Permanent marker / masking tape (for labeling connectors and hoses)
Phone/camera (take photos before disassembly!)
2.5L Engine Note: The 2013 Mazda5 with the 2.5L engine uses a single serpentine belt with an automatic spring-loaded tensioner. You do NOT need the special Mazda SST stretch-belt tools (49 B015 102, 103, 104) — those are only for the MZR 2.0L engine. A simple breaker bar and socket is all you need for belt removal/installation.
Section 3 — Preparation
Park on a flat, level surface — concrete driveway or garage floor is ideal. Avoid gravel, grass, or slopes.
Engage the parking brake and place wheel chocks behind both rear wheels.
Let the engine cool completely — ideally let the car sit for 2+ hours, or overnight. You'll be draining coolant and don't want to get burned.
Disconnect the negative battery cable using a 10mm wrench. The negative terminal is marked with a “−” symbol and typically has a black cable. Tuck the cable away so it can't accidentally touch the terminal. Wait at least 1 minute before proceeding.
Gather all parts and tools — lay them out organized. Nothing worse than realizing you're missing a part with everything disassembled.
Take photos of everything before you start removing anything:
Serpentine belt routing (there may also be a sticker diagram in the engine bay)
All hose and connector locations
Wiring harness routing
AC line connections
Bumper fastener locations
Pro Tip: Label every connector, hose, and bolt location with masking tape and a marker as you go. It makes reassembly much less stressful, especially if this job spans multiple days.
Section 3.5 — Refrigerant Recovery (DIY)
Before you can open any refrigerant line, you must first recover all the R-134a from the system. Venting refrigerant to the atmosphere is illegal and carries severe fines.
What You Need: AC Recovery Machine (~$300–500)
A recovery machine is a self-contained unit with its own compressor, storage tank, filter, and gauges. It pumps refrigerant out of your car's AC system and stores it for reuse or recycling. This is the standard way to do it — straightforward, reliable, and fast.
VEVOR AC Recovery Machine (R134a/R1234yf)Fully automatic with built-in tank, scale, and filter. The most popular DIY option.Search Amazon
Other brands: Robinair, YellowJacket, Mastercool (~$200–400 for recovery-only units).
Alternative: Check local tool rental shops, or buy a used unit on eBay/Facebook Marketplace.
Recovery Procedure
Connect the machine's hoses to the vehicle's high-side and low-side AC service ports (see Section 11 for port locations).
If the machine uses an external storage tank, connect it to a DOT-approved recovery tank.
Turn on the machine — it will automatically pull the refrigerant out of the vehicle and store it in its internal or external tank.
Let it run until the machine auto-shuts off (system pressure reaches ~0 psi or a slight vacuum).
Wait 5 minutes, then check if the pressure rises on your gauges. If it does, run the machine again until pressure holds steady at 0.
Done! The refrigerant is now safely stored and can be reused when you recharge the new system.
Pro Tip: Many of these machines (especially the VEVOR units) can also handle the evacuation and charging steps later in Section 11, so the machine pays for itself across the whole job.
Section 4 — Remove Aerodynamic Under Cover
Workshop Manual Reference: 09-16-32
The aerodynamic under cover is the large plastic shield that covers the underside of the engine bay. It must be removed to access the compressor from below.
Raising the Vehicle
You need to get under the front of the car. You have two options:
Option 1: Drive-on ramps — easiest if you have them. Drive front wheels up, set parking brake, chock rear wheels.
Option 2: Floor jack + jack stands:
Place wheel chocks behind both rear wheels.
Position the floor jack under the front crossmember (the large metal beam running left-to-right behind the front bumper).
Jack up the front of the car until you have comfortable working space underneath (~12–18 inches).
Place jack stands under the front pinch welds (the reinforced seam running along the bottom edge of the body, just behind each front wheel). The owner's manual shows these locations.
Lower the car onto the jack stands. Wiggle the car to confirm it's stable before getting underneath.
NEVER work under a car supported only by a floor jack. Jacks can fail. Always use jack stands.
Under Cover Removal Steps
Remove screws A — multiple small Phillips-head screws along the front edge of the cover.
Remove bolts B — 3 bolts (torque spec: 4.5–7 Nm / 40–62 in-lbf). Use a 10mm socket.
Remove fasteners C — these are push-pin clips (also called "Christmas tree clips"). To remove them:
Use a trim removal tool or flathead screwdriver
Pry up the center pin first (it pops up about 3mm)
Then pull the entire clip out
Be gentle — these clips are reusable but break easily
Pull the under cover straight down and set it aside.
Step 1: Remove screws AStep 2: Remove bolts B (4.5–7 Nm)Steps 3–4: Remove fasteners C & pull down
Section 5 — Remove Splash Shield
Workshop Manual Reference: 09-16-36
The front splash shields are the plastic panels inside each front wheel well. You may need to remove them (or at least fold them back) for better access to the compressor and condenser area.
Turn the steering wheel to one side to expose the inner fender area.
Remove screws A, screw B, and fastener C — as shown in the diagram.
Pull the splash shield free and set aside.
Repeat on the other side if needed.
Front splash shield — Screw A (top, 2 locations), Screw B (bottom), Fastener C (top center) all labeled
The 2.5L engine uses a single serpentine belt that drives everything: alternator, AC compressor, water pump, and power steering. It has an automatic spring-loaded tensioner — a spring-loaded pulley that maintains constant belt tension. To remove the belt, you simply release the tensioner.
Before touching the belt, photograph or sketch the belt routing. There's usually a routing diagram on a sticker in the engine bay (on the radiator support or underside of the hood). If not, photograph it from the front of the engine.
Locate the automatic belt tensioner — it's a small idler pulley on a spring-loaded arm, typically on the passenger side of the engine.
Place a breaker bar or long-handle ratchet with the correct socket (typically 15mm or 19mm) on the tensioner pulley bolt.
Rotate the tensioner to release tension on the belt. (Direction varies — usually clockwise when viewed from the front of the engine. The tensioner arm will compress.)
While holding the tensioner back, slip the belt off the easiest pulley (often the alternator or the tensioner pulley itself).
Slowly release the tensioner arm.
Remove the belt completely.
Pro Tip: If you're replacing the belt (recommended if it shows cracks, glazing, or fraying), just cut the old one off — it makes removal much easier and you won't need it again.
Video Reference: For a visual of the serpentine belt procedure on the Mazda 2.5L, search YouTube for "Mazda 3 2.5 serpentine belt replacement" — the 2013 Mazda3 uses the same engine/layout as the Mazda5.
Drive belt system overviewBelt removal procedure
Step 6b — Remove Water Hose Bracket
There's a bracket near the compressor that holds a coolant/water hose in place. Remove the bolt holding this bracket to move the hose out of the way. Simple bolt removal — just moves things aside for clearance.
Locate the wire harness clip on the compressor. It's a small retaining clip that holds the wiring harness in place.
Remove the clip (squeeze or pry with a small screwdriver).
Disconnect the electrical connector: press the locking tab on the connector and pull it straight off. Don't yank on the wires.
Water hose bracket, connector, and clip locations on compressor
Step 6d — Disconnect Refrigerant Lines
There are two refrigerant lines connected to the compressor:
Cooler hose (HI) — the high-pressure discharge line (smaller diameter, hot during operation)
Cooler hose (LO) — the low-pressure suction line (larger diameter)
For block joint type connections (most common on the Mazda5):
Hold the female side of the block fitting firmly with pliers or a wrench to prevent it from spinning.
Remove bolt A (torque spec: 6.9–9.8 Nm / 62–86 in-lbf).
Carefully separate the line from the compressor.
For spring lock coupling type connections (if equipped):
Insert the spring lock disconnect tool around the line.
Push the tool inward to compress the garter spring inside the coupling.
While holding the tool in place, pull the male fitting out of the female fitting.
Cap or plug all open fittings. While the vacuum evacuation in Section 11 will pull out residual moisture, capping the fittings keeps dirt, debris, and bugs out of the lines while you work. Use rubber caps, clean rags secured with zip ties, or plastic wrap + rubber bands. This is especially important if the job spans more than one day.
Block joint type (top) and spring lock coupling type (bottom) — how to disconnect eachRefrigerant line bolt, clip, cooler hose HI & LO at compressor
Step 6e — Remove Compressor Mounting Bolts
Remove bolt B (and any additional mounting bolts) — torque spec: 18–26 Nm (14–19 ft-lbf). There are typically 3–4 bolts holding the compressor to the engine block/bracket.
Support the compressor with one hand as you remove the last bolt — it's heavy (about 10–15 lbs).
Carefully lower the compressor out through the bottom of the engine bay (through the space where the under cover was).
Pro Tip: Place a drain pan under the compressor as you remove it. Some residual oil will drip out. Keep the old compressor — you'll need to drain and measure its oil in Step 9a.
Compressor Bolt A (refrigerant line, 6.9–9.8 Nm), Bolt B & Nut (mounting, 18–26 Nm), Cooler Hose HI & LO
Section 7 — Condenser Removal
Workshop Manual Reference: 07-11-28
The condenser sits directly in front of the engine radiator. To remove it, you must remove several components first, then lift the radiator and condenser out together as a unit, then separate them on a workbench.
Step 7a — Remove Plug Hole Plates
Reference: 01-10A-4
These are the plastic/rubber covers on top of the engine that cover the spark plug holes (also called "coil covers" or "engine covers").
Simply lift each plate upward — they sit in rubber grommets/clips.
No tools needed — just pull firmly upward.
Set aside.
Plug hole plate — lift straight up to remove
Step 7b — Remove Air Cleaner & Fresh Air Duct
Reference: 01-13A-5
The air cleaner assembly (airbox) and its intake ducts need to come out for clearance to access the radiator and condenser.
Disconnect the MAF (Mass Air Flow) sensor electrical connector — press the tab and pull.
Remove the screws and clips holding the air cleaner cover.
Remove the air filter element (good time to inspect/replace it).
Remove the bolts holding the air cleaner box to the vehicle.
Disconnect and remove the fresh air ducts (the intake tubes that connect the airbox to the throttle body). There are typically two pieces (No.1 and No.2).
Set everything aside in order.
Air cleaner assembly overviewAir cleaner removal stepsFresh air duct removal
Step 7c — Drain Engine Coolant
Reference: 01-12A-4
WARNING: The engine MUST be completely cool! Hot coolant is under pressure and will spray out, causing severe burns. If the engine has been running, wait at least 2 hours.
Remove the cooling system cap (on the radiator, typically on the passenger side). Turn it slowly and let any residual pressure release before fully removing. "What's the cooling system cap?" — it's the round cap on top of the radiator filler neck, usually near the upper radiator hose.
Place a large drain pan (at least 1 gallon / 4 liter capacity) under the bottom of the radiator.
Locate and open the radiator drain plug (petcock). It's at the bottom of the radiator, usually on the driver's side. It looks like a small plastic wingnut or valve.
Turn it counterclockwise to open. Some have a small nipple you can attach a hose to for a cleaner drain.
Let the coolant drain completely — approximately 3.8 liters will come out. This takes 5–10 minutes.
Close the drain plug when finished. Don't leave it open — you'll forget later.
Coolant is toxic to animals. It tastes sweet and is attractive to pets. Keep drain pans covered and clean up any spills immediately. Dispose of old coolant properly (most auto parts stores accept it for recycling).
The cooling fan assembly sits between the radiator and the engine. It must come out before you can remove the radiator.
Disconnect the cooling fan motor connectors. There are typically 2 fans (No.1 and No.2), each with its own electrical connector. Press the tab and pull.
Disconnect the wiring harness from its routing clips.
Remove the mounting bolts (various sizes, torque specs range from 2.8–5.0 Nm to 5.9–8.3 Nm depending on the bolt).
Remove the cooling fan assembly — it comes out from below the engine compartment (drop it down).
Cooling fan assembly — Components 1–8 labeled: (1) Water pump pulley, (2) Water hose, (3) Cooling fan component, (4) Cooling fan No.1, (5) Cooling fan No.2, (6) Cooling fan motor No.1, (7) Cooling fan motor No.2, (8) Radiator cowling. Bolt torque specs shown at each mounting point.Cooling fan motor removal procedure — water pump bolt locations also visible
Step 7e — Disconnect Condenser Refrigerant Lines
Disconnect the cooler hose (HI) from the condenser — block joint type connection. Same procedure as Step 6d: hold the female side, remove bolt A.
Disconnect the cooler pipe from the condenser.
Cap or plug the open fittings to keep debris out while you work.
Caution: Some compressor oil will be present in the lines and condenser. Catch any drips with a rag — you don't want oil on the belts or engine.
Full refrigerant line layout — Cooler Hose HI (1), Cooler Hose LO (2), Cooler Pipe (3) — Bolt A: 6.9–9.8 NmEngine bay view — physical location of Cooler Hose HI (1), Cooler Hose LO (2), Cooler Pipe (3), and refrigerant pressure sensor connector. Bolt A: 6.9–9.8 Nm.
The condenser is hooked onto the front of the radiator via tabs. They come out as a single unit.
Remove the cooling system filler neck — unbolt and set aside.
Remove the filler hose.
Disconnect the upper radiator hose (squeeze the clamp with pliers, slide it back, then pull the hose off).
Disconnect the lower radiator hose (same method).
Disconnect the automatic transmission cooler lines from the radiator (two metal lines on the lower portion of the radiator). Have a rag ready — some ATF will drip out. These are typically held on with spring clamps or flare nuts.
Remove the radiator mounts:
These are rubber-mounted brackets at the top of the radiator.
Press the tabs inward, then lift the mount upward to release.
Carefully lift the radiator + condenser assembly straight up and out of the engine bay. This is a two-person job — have a helper support one side.
Important: Note the arrow on the radiator mount — it must point toward the front of the vehicle when reinstalling.
Radiator and filler neckRadiator hoses and mountsRadiator mount tab detail
Step 7g — Separate Condenser from Radiator
Lay the radiator/condenser assembly on a clean, padded surface (cardboard or towels). The condenser is aluminum and dents easily.
Look at the lower edge of where the condenser meets the radiator. There are left and right tabs — press them to release.
The condenser hooks onto the upper edge of the radiator at left and right insertion points. Lift the condenser upward to unhook it.
Set the old condenser aside. Keep the radiator — you'll hook the new condenser onto it later.
Condenser/Radiator separation — receiver/drier locationCondenser hook and tab details
Section 8 — Receiver/Drier Removal
Workshop Manual Reference: 07-11-30
The receiver/drier is a cylindrical canister located near the condenser, behind the front bumper. To access it, the front bumper must come off.
Step 8a — Front Bumper Removal
Reference: 09-10-14
Pro Tip: Have a helper ready to support the bumper as it comes free. It's large, awkward, and surprisingly flexible — easy to drop or scratch.
Disconnect the negative battery cable (if not already done).
Remove fastener A — top clips along the upper edge of the bumper (where it meets the hood area). These are push-pin clips — pry up the center, then pull the whole clip out.
Remove screw B — located under the headlight area, both sides.
Remove screw C — located in the wheel arch area, both sides. You may need to turn the steering wheel for better access.
Remove bolt D — underneath the bumper.
Remove fastener F — additional clip.
Pull the bumper off:
First, disengage the sides (pull each side outward at the fender junction).
Then, disengage the top (pull forward at the top edge near the headlights).
Finally, pull the entire bumper straight forward.
Before fully separating, reach behind and disconnect:
Fog light connectors (if equipped) — press tab, pull.
Headlight washer hose (if equipped) — pull off the rubber connection.
Set the bumper in a safe location on a blanket/cardboard (face down is usually best).
Fastener A and Screw B locationsScrew C (both sides, underneath), Bolt D, and Fastener F locationsBumper pull sequenceBumper reinstallation — spread ends apart, press onto front bumper slider (reverse for removal)
Step 8b — Remove Receiver/Drier
With the bumper off, the receiver/drier is now accessible.
Disconnect the block joint type pipes: hold the female side firmly with pliers/wrench, remove bolt A (6.9–9.8 Nm / 62–86 in-lbf).
Remove bolt B and the mounting bracket.
Pull the receiver/drier out. Cap or plug the open pipe fittings to keep debris out.
Receiver/drier — Bolt A (refrigerant pipe, 6.9–9.8 Nm), Bolt B (bracket), and location
Section 9 — Installation (Reassembly)
Now we install the new components. Installation is essentially the reverse of removal, but with some critical steps for the AC system specifically.
Critical Rules for AC Installation:
Replace ALL O-rings at every connection with new ones from your kit.
Apply a thin film of PAG 46 compressor oil to each new O-ring before installing — this helps them seal and prevents tearing.
Keep fittings clean — do NOT let debris, dirt, or metal shavings enter any open fitting. Even a small piece of grit can cause a leak or damage the new compressor.
Step 9a — Prepare New Compressor (CRITICAL Oil Balancing Procedure)
New compressors come pre-filled with oil, but usually too much for your system. You need to balance the oil amount to match what was in your old system.
Take the NEW compressor. Remove the cap from the suction port. Rotate the compressor shaft by hand (using a wrench on the clutch center bolt) 6–8 full revolutions. This pumps oil out of the internal chambers.
Pour the oil that comes out into a clean measuring cup. Note the amount. This is the "new compressor oil amount."
Take the OLD compressor. Rotate its shaft 6–8 revolutions. Collect that oil in a separate clean container. Note the amount. This is the "old compressor oil amount."
Compare:
The new compressor should have more oil than what came out of the old one.
If the old compressor is seized and you can't rotate the shaft: skip measuring the old one. Instead, drain and measure only the new compressor, then pour back approximately 80–90 ml (roughly 2/3 of the total 120 ml system capacity, since some oil remains distributed in the lines and evaporator).
If the old compressor turns but very little oil comes out, that's normal — oil migrates throughout the system during operation.
Pour the same amount of oil that came out of the OLD compressor back into the NEW compressor through the suction port. (Or use the 80–90 ml estimate if the old compressor was seized.)
Oil type: FD46XG / PAG ISO 46
Total sealed system volume: 120 ml (4.06 fl oz)
Do this quickly! PAG oil absorbs moisture from the air rapidly. Complete the oil transfer and re-cap the compressor within 10 minutes. Work in a dry environment if possible.
Add 35 ml of supplemental PAG 46 oil into the new condenser (pour it into the inlet fitting). This replaces oil that was trapped in the old condenser.
With the radiator laying on a flat surface, position the new condenser in front of it.
Hook the condenser onto the radiator at the upper left and right insertion points (the condenser hooks over the top edge of the radiator).
Press the lower tabs into place until they click/snap.
Verify the condenser is firmly attached and aligned with the radiator.
Step 9c — Install Radiator/Condenser Assembly
With a helper, lower the radiator (with new condenser) back into the engine bay.
Seat the radiator into the shroud panel installation holes at the bottom.
Install the radiator mounts:
Remember: Arrow must point toward the front of the vehicle!
Press tabs inward to lock.
Reconnect the lower radiator hose — push on fully, slide clamp back into position.
Reconnect the upper radiator hose — same method.
Reconnect the ATF cooler lines to the lower portion of the radiator.
Reinstall the filler hose and filler neck (bolts: 8–10 Nm).
Radiator mount installation — the arrow on the mount MUST point toward the front of the vehicle.Radiator mount tab detail — press tab in direction of arrow to lift mount. Also shows condenser-to-radiator insertion areas and tab locations.
Step 9d — Reinstall Cooling Fan Assembly
Slide the fan assembly up from below into position between the radiator and engine.
Install all mounting bolts and torque to spec (2.8–8.3 Nm range, varies by bolt).
Reconnect both fan motor connectors (you'll hear a click when they lock).
Route the wiring harness back through the original clips.
Cooling fan assembly — bolt torque specs shown at each mounting point. See Step 7d for component reference.
Step 9e — Install New Receiver/Drier
Important: Don't remove the caps from the new receiver/drier until you're ready to connect the lines. The desiccant inside absorbs moisture quickly once exposed to air.
Position the new receiver/drier and install with the bracket and bolt B.
Install new O-rings on the pipe fittings. Apply a thin coat of PAG 46 oil to each O-ring.
Connect the block joint pipes and tighten bolt A: 6.9–9.8 Nm (62–86 in-lbf).
Receiver/drier — Bolt A (refrigerant pipe, 6.9–9.8 Nm) and Bolt B (mounting bracket). See Step 8b for reference.Block joint installation — hold female side with pliers, tighten bolt with torque wrench. Also shows spring lock coupling installation and supplemental oil amounts (Cooler Hose LO: 10 ml, Cooler Pipe: 5 ml).
Reconnect fog light connectors and headlight washer hose (if equipped).
Align the bumper and engage the top sliders/hooks first.
Press in the sides at the fender junctions until they click into place.
Reinstall all fasteners: bolt D, screw C (both sides), screw B (both sides), fasteners A and F.
Check alignment — gaps should be even on both sides.
Step 9f — Install New Compressor
Lift the new compressor into position from below.
Install mounting bolts B and torque to 18–26 Nm (14–19 ft-lbf). Start all bolts finger-tight first, then torque in a cross pattern.
Install new O-rings on both refrigerant line connections. Apply PAG 46 oil.
Connect the refrigerant lines and tighten bolt A: 6.9–9.8 Nm.
Reconnect the electrical connector (push until it clicks).
Reinstall the wiring harness clip — engage to 3 or more teeth to lock.
Reinstall the water hose bracket.
Compressor mounting — Bolt A (refrigerant lines, 6.9–9.8 Nm), Bolt B/Nut (mounting, 18–26 Nm), Cooler Hose HI and Cooler Hose LO connections. See Step 6e for reference.Water hose bracket, electrical connector, and wiring clip locations at the compressor.
Step 9g — Drive Belt Installation (2.5L)
Route the belt according to the belt routing diagram (from your photo or the engine bay sticker). Make sure it wraps around every pulley in the correct pattern — getting this wrong can cause immediate damage.
Leave the belt off one pulley (typically the tensioner pulley or alternator).
Place the breaker bar on the auto-tensioner bolt and rotate to release tension.
Slip the belt onto the last pulley.
Slowly release the tensioner — it will automatically apply the correct tension.
Verify: Check that the belt is properly seated in ALL pulley grooves. A misaligned belt will squeal, throw off, or cause damage.
Rotate the crankshaft clockwise by hand for 2 full rotations (use a socket on the crankshaft pulley bolt) to verify the belt tracks correctly and doesn't interfere with anything.
NEVER rotate the crankshaft counterclockwise — this can loosen the crankshaft bolt.
Step 9h — Reinstall Remaining Components
Air cleaner and fresh air duct — reverse of Step 7b. Reconnect the MAF sensor.
Plug hole plates — push down into the rubber grommets.
Aerodynamic under cover — reinstall fasteners C, bolts B, screws A (Section 4).
Reconnect negative battery cable — tighten the 10mm nut securely.
Section 10 — Refill Engine Coolant
Workshop Manual Reference: 01-12A-4
Verify the radiator drain plug is closed/tight.
Prepare coolant mixture:
Climate
Coolant %
Water %
Freeze Protection
Moderate (most US areas)
55%
45%
-37°C / -35°F
Severe cold
60%
40%
-51°C / -60°F
Hot climate / no freeze risk
50%
50%
-37°C / -35°F
Use Mazda FL22 or equivalent long-life coolant. Use distilled water (not tap water) for the mix. Or buy pre-mixed coolant.
Pour coolant slowly into the radiator filler neck until the level reaches near the top. Go slowly — air bubbles need time to escape.
Fill the coolant reserve tank (the translucent plastic tank with MIN/MAX marks) to the "F" (Full) mark.
Install the cooling system cap.
Start the engine and let it warm up to operating temperature (the temperature gauge will reach its normal position).
Run the engine at 2,500 RPM for 5 minutes. This circulates coolant and helps push air bubbles out.
Then: Rev to 3,000 RPM for 5 seconds, then return to idle. Repeat this 3–5 times. This "burping" procedure helps purge trapped air from the system.
Turn off the engine and let it cool completely.
Check the coolant level again — top up if needed (both radiator and reserve tank).
Check for leaks at all hose connections and the drain plug.
Pro Tip: Check the coolant level again after driving for a day or two. Air pockets may work themselves out and the level may drop slightly. Top up as needed.
Section 11 — Evacuate & Charge AC System
Workshop Manual Reference: 07-10
This is the final step for the AC system. You'll pull a deep vacuum to remove all air and moisture, then charge with the exact amount of R-134a refrigerant.
What are the "service ports"? Your car has two AC service ports with protective caps:
Low-pressure port — larger diameter fitting, usually located near the firewall (back of engine bay) on the suction line. Has an "L" marking or blue cap.
High-pressure port — smaller diameter fitting, usually located near the condenser (front of engine bay) on the discharge line. Has an "H" marking or red cap.
Connect the blue (low-side) hose to the low-pressure service port.
Connect the red (high-side) hose to the high-pressure service port.
Connect the yellow (center) hose to the vacuum pump.
Step 2: Evacuate the System
Make sure the engine is OFF.
Open both manifold valves (blue/low and red/high).
Turn on the vacuum pump.
Let it run for at least 30 minutes (45–60 minutes is better, especially if the system was open for a while).
Verify the low-side gauge reads -101 kPa / -29.8 inHg or lower. This confirms a deep vacuum.
Close both manifold valves.
Turn off the vacuum pump.
Wait at least 5 minutes and watch the gauges.
Leak Check: If the pressure rises during the 5-minute wait, you have a leak. Do NOT proceed with charging. Find and fix the leak first. Common leak points: O-ring connections (try re-torquing bolts), service port Schrader valves, or a defective new component. Use your electronic leak detector to pinpoint.
If the vacuum holds steady: Congratulations! Your system is sealed and moisture-free. Proceed to charging.
Step 3: Charge with R-134a
Disconnect the yellow center hose from the vacuum pump.
Connect it to the R-134a refrigerant can (using a can tap/valve if using small cans, or a dispenser if using a large can).
Place the refrigerant on your digital scale. Note the starting weight.
Purge the center hose: Briefly crack the center hose fitting at the manifold to let refrigerant push air out of the hose, then retighten. (This ensures no air enters the system.)
Open the low-side (blue) valve ONLY.
Refrigerant will flow into the evacuated system on its own (engine OFF). Let it flow until the pressures equalize and flow stops.
Now start the engine.
Turn the AC to MAX COLD, fan to MAX speed, set to recirculate mode.
Open the low-side valve and continue charging through the low side.
Shake/invert the can gently to help liquid refrigerant flow out faster.
When a can runs empty, close the valve, swap the can, purge the hose again, and continue.
Charge until the scale shows 480g (16.9 oz) total has been added.
NEVER open the high-side (red) valve with the engine running! The high side can be at 200+ psi. Opening it could cause the refrigerant can to explode and/or severely injure you. Low side ONLY when the engine is running.
Step 4: Disconnect and Finish
Close both manifold valves.
Turn off the engine.
Disconnect the gauge hoses from the service ports (a small hiss as residual hose pressure releases is normal).
Reinstall the protective caps on both service ports. Finger-tight is fine.
Refrigerant system — service overviewEvacuation procedureCharging procedureSystem performance test
Section 12 — Final Testing & Verification
Start the engine and let it idle at approximately 1,500 RPM (slight throttle or fast idle is fine).
Set AC to MAX COLD, fan on MAX HI, recirculate mode, all windows closed.
Let the system run for 5–10 minutes to stabilize.
Check vent temperature with a thermometer inserted into the center dash vent:
Target: 35–45°F (2–7°C) depending on ambient temperature.
On a hot day (90°F+), 45–50°F is acceptable.
If vent temp is above 55°F, there may be an issue (undercharge, air in system, or a leak).
Listen for unusual compressor noises:
Clicking/rattling: may indicate debris in the system or a clutch issue.
Grinding/squealing: bearing failure or belt issue.
Normal sound: a slight hum/drone when the compressor clutch engages.
Leak check: Use your electronic leak detector to sniff around every refrigerant connection point (compressor fittings, condenser connections, receiver/drier, service ports).
Check coolant level and connections: Look for any drips at radiator hoses, drain plug, and filler neck.
Verify cooling fans cycle on: As the AC runs, the condenser fan should be running. The radiator fan should cycle on when coolant temperature rises.
Take a test drive: Drive for 15–20 minutes with AC running. Check for consistent cooling. Check under the car when you return — a small puddle of clear water (condensation from the evaporator drain) is normal and expected.
Success! If you're getting cold air, no leaks, no strange noises, and the engine temperature is normal — you're done! Give yourself a well-deserved pat on the back. This is a serious DIY job and you nailed it.
Section 13 — Torque Reference Table
All torque specifications in one place for quick reference during the job.
Connection
Torque (Nm)
Torque (Imperial)
Refrigerant line bolt A (block joint)
6.9 – 9.8 Nm
62 – 86 in-lbf
Compressor mounting bolt B
18 – 26 Nm
14 – 19 ft-lbf
Radiator mount / hose bolts
8 – 10 Nm
71 – 88 in-lbf
Under cover bolts B
4.5 – 7 Nm
40 – 62 in-lbf
Floor under cover bolts A / nuts B
8 – 10 Nm
71 – 88 in-lbf
Cooling fan bolts (various)
2.8 – 8.3 Nm
25 – 73 in-lbf
Cooling system filler neck
8 – 10 Nm
71 – 88 in-lbf
Pro Tip: When in doubt, remember: refrigerant fittings are delicate aluminum — they need to be snug, not gorilla-tight. Over-tightening will crack the fitting or crush the O-ring. Use a torque wrench on all AC connections.
Section 14 — Video & Web References
Supplementary resources organized by topic. Watch the relevant videos before starting each section to get a visual understanding of the procedures.