How to Change the AC Compressor on a 1992 Mazda 626

The 1992 Mazda 626 came with a 2.2-liter four-cylinder engine and a five-speed manual or four-speed automatic transmission. The air conditioning compressor for your 626 is located on the right side of the engine and can be accessed from the top side of the vehicle. Your air conditioning system uses a refrigerant that is harmful to the atmosphere and it must be drained and filled by a licensed facility with the proper equipment.

Instructions

Drive the vehicle to a local repair shop and have the air conditioning system evacuated.

Park the vehicle on a level surface and set the parking brake. Lift the hood and support it with the hood prop rod. Disconnect the negative battery cable with the socket and ratchet. Locate the air conditioning compressor on the lower right-hand side of the engine.

Squeeze the locking tabs for the clutch connector and disconnect the harness from the air conditioning compressor. Loosen the compressor mounting bolts with the socket and ratchet. Tilt the compressor slightly toward the crankshaft and remove the air conditioning compressor drive belt.

Loosen the mounting bolts for both air conditioning lines with the socket and ratchet. Disconnect the lines from the air conditioning compressor. Remove the a/c compressor bolts and remove the air conditioning compressor from the engine bay.

Pry up on the center of the push pins securing the center grille to the core support with the flat-head screwdriver. Lift the push pins out of the grille and core support. Pull up on the grille carefully to release the lower clamps. Remove the grille from the vehcile.

Disconnect the air conditioning lines from the receiver/drier with the socket and ratchet. Loosen the clamp for the receiver/ drier with the socket and ratchet. Lift the receiver and dryer from the bracket.

Pour 3.8 ounces of PAG 500 refrigerant oil into a measuring cup. Fill the air conditioning compressor with the oil in the measuring cup by pouring it into the larger of the two compressor line fittings while rotating the clutch to help work the oil into the compressor. Allow the compressor to sit clutch down for at least 10 minutes.

Set the new receiver/drier into the bracket and tighten the clamp with the socket and ratchet. Install both air conditioning lines and tighten them to 11 to 18 foot-pounds with the torque wrench. Press the lower part of the grille into the retaining clamps and lower the top of the grille to the core support. Install the push pins and push the center pin until it sits flush with its base.

Set the air conditioning compressor into position and loosely install the mounting bolts. Install the belt onto the compressor pulley and tilt the compressor away from the crankshaft to tighten the belt. Tighten the belt so that there is 7 to 9 mm of deflection for a new belt and 8 to 10 mm of deflection in the middle of the belt with a 2.2 pound push.

Tighten the lock bolts to 27 to 38 foot-pounds with a torque wrench. Plug in the magnetic clutch connector. Install the negative battery cable and tighten with the socket and ratchet.

Shut the vehicle hood. Drive the vehicle to a local repair shop to have the air conditioning system properly filled.