07-001/03 1998-2003 MULTIPLE MODELS: AIR CONDITIONING - MUSTY / MILDEW ODOR

Note: This bulletin supersedes the following TSB(s): 07-004/02. Please update your records accordingly.

BULLETIN NOTE

• This bulletin supersedes 07-004/02, issued 8/30/02. The 2003 Model Year has been added and Tribute has been removed.

APPLICABLE MODEL(S)/VINS

• 1998-2002 626
• 1998-2003 Protege
• 2002-2003 Protege5
• 2000-2003 MPV
• 1998 MPV
• 1998-2002 Millenia
• 1999-2003 Miata

DESCRIPTION

A musty/mildew type odor may come from the vents when the air conditioning (A/C) system is operating. It is most noticeable when the A/C is first turned ON. This odor is the result of mold growth in the A/C evaporator/cooling unit which is caused by condensation, dust, and pollen within the cooling unit. This condition is usually worse during high humidity conditions. "Mazda Air Cooling Coil Coating" is available to encapsulate the mold to reduce odors. If the product is properly applied, it can effectively reduce the musty/mildew odor for up to three years.

NOTE: See parts information for Mazda Air Cooling Coil Coating and Kit part numbers.

This treatment provides a durable coating that will aid to prevent biological reactions that lead to odor concerns. It is applied to the evaporator in a misted form that is introduced by way of the re-circulate door, the blower motor resistor access, or the blower motor air intake (on rear a/c only). Proper application requires the evaporator.

• Surface to be relatively clean and free of leaves, dust build-up and debris.
• To be thoroughly dried, and the product cured onto it after application.

NOTE:

• A/C odor is not unique to Mazda vehicles as it will occur in other makes and models.
• To minimize A/C odor, inform customers of the following suggestions:
  • Keep the cooling unit dry by leaving the blower fan ON (at least on low), even if the A/C is not being used.
  • In low humidity (dry) conditions, keep the ventilation system in the "FRESH" mode all the time, or as much as possible.
  • In high humidity conditions, or if the air has a lot of dust or pollen, keep the system in the "RECIRCULATION" mode.
  • A few minutes before reaching a destination, turn the A/C OFF, but leave the blower fan ON. This stops the accumulation of condensation on the evaporator/cooling unit, and it helps dry the inside of the cooling unit.

Customers having this concern should have their vehicle repaired using the following procedure.

REPAIR PROCEDURE

1. Verify customer concern.

2. Verify that evaporator drain has no blockage.

3. Apply "Mazda Air Cooling Coil Coating" according to the attached instructions. Refer to the table below for the applicable repair instructions.

   Repair Procedure	Page(s)
   1998-2002 626	4-5
   1998-2003 Protege & Protege5	6-7
   2000-2003 MPV Front A/C	8-9
   2000-2003 MPV Rear A/C	10
   1998 MPV Front A/C	11-12
   1998 MPV Rear A/C	13
   2001-2002 Millenia	14-16
   1998-2000 Millenia	17-18
   1999-2003 Miata	19-20

   NOTE:

   • Follow attached instructions completely to ensure an effective repair. If insufficient care is taken on the drying sequence of product, the coating will not last, and the concern will reoccur.
   • If odor is still present after treatment, it may be necessary to remove and clean evaporator, evaporator foam, and inside of cooling unit housing with a mild dish soap and water solution. To avoid damage to components, do not clean with bleach. See Workshop Manual section 07 for removal instructions.

   WARNING:

   • When using this product, avoid skin and eye contact. Wear safety glasses and gloves, and avoid breathing vapors.
   • Read all the safety and first aid instructions on the back of the Mazda bottle.

4. Verify repair.

PART(S) INFORMATION

Part Number	Description	Qty.	Notes
0000-77-570K-01	Mazda Air Cooling Coil Coating Kit	1	Includes applicator, pressure regulator, and 4- bottles of Mazda Air Cooling Coil Coating 118 ml (4 fl oz)
0000-77-550E-01	Mazda Air Cooling Coil Coating	1= (4 bottles)	Replacement bottles 118 ml (4 fl oz), requires one-bottle per vehicle (two-bottles required for MPV with rear air)

WARRANTY INFORMATION

NOTE: This repair is not covered by warranty.

1998-2002 626

1. Dry evaporator using the following procedure:

   WARNING: Running the engine inside an enclosed area, such as a garage, is dangerous. Exhaust gas, which contains poisonous carbon monoxide, could easily enter the cabin. Loss of consciousness or even death could occur. Don't run the engine when inside an enclosed area.

   1. Start engine.
   2. Set HVAC controls as follows:
      • RECIRCULATE
      • FULL HEAT
      • FAN HIGH
      • A/C OFF
      • AIRFLOW (FACE)
   3. Open one window approximately ".
   4. Let engine run for 20 minutes.

2. Remove glove box by:
   1. Pushing top stops inward (plastic will flex).
   2. At right side hinge, lift clip out of its seat.
   3. Pull left side axle pin out towards right side and remove glove box.

3. Shake bottle of Mazda Air Cooling Coil Coating well and attach it to applicator. Then connect applicator to compressed shop air.

4. Insert applicator in grille of recirculation door. Point nozzle tip downwards (approximately at the 7 o'clock position) and towards the center of cooling unit.

5. Spray entire contents of bottle in short bursts, 3 seconds ON, 3 seconds OFF into rotating fan. A fine mist may exit from ducts.

6. When bottle is empty, stop engine and remove applicator. Let vehicle sit for 10 minutes.

   NOTE: For reuse, clean the applicator by flushing a bottle of clean water through it.

7. Use STEP 1 to dry and cure product.

8. While product is drying, re-install glove box.

9. Note application date in service record.

1998-2003 Protege & Protege5

1. Dry the evaporator using the following procedure:

   WARNING: Running the engine inside an enclosed area, such as a garage, is dangerous. Exhaust gas, which contains poisonous carbon monoxide, could easily enter the cabin. Loss of consciousness or even death could occur. Don't run the engine when inside an enclosed area.

   1. Start engine.
   2. Set HVAC controls as follows.
      • RECIRCULATE
      • FULL HEAT
      • FAN HIGH
      • A/C OFF
      • AIRFLOW (FACE)
   3. Open one window approximately ".
   4. Let engine run for 10 minutes.

2. Remove glove box by:
   1. Pushing top stops inward (plastic will flex).
   2. At left side hinge, lift clip out of its seat.
   3. Pull right axle pin out towards left side and remove glove box.

3. Stop engine. Switch OFF fan motor.

4. Remove fan resistor and inspect evaporator for debris; remove debris using an appropriate vacuum cleaner

   WARNING: Blower motor resistor may be extremely hot.

5. Reinstall fan resistor.

6. Shake bottle of Mazda Air Cooling Coil Coating well and attach it to applicator. Then connect applicator to compressed shop air.

7. Insert applicator in grille of recirculation door. Point nozzle tip in direction of evaporator.

8. Switch fan motor ON.

9. Begin spraying by gently moving nozzle tip in front of the evaporator surface. Spray entire contents of bottle in short bursts, 3 seconds ON, 3 seconds OFF onto evaporator. A fine mist may exit from ducts.

10. When bottle is empty, switch fan motor off, and remove applicator. Turn engine off and let vehicle sit for 10 minutes.

    NOTE: For reuse, clean the applicator by flushing a bottle of clean water through it.

11. Reinstall glove box.

12. Use STEP 1 to dry and cure product.

13. Note application date in service record.

2000-2003 MPV Front AC

1. Dry evaporator using the following procedure:

   WARNING: Running the engine inside an enclosed area, such as a garage, is dangerous. Exhaust gas, which contains poisonous carbon monoxide, could easily enter the cabin. Loss of consciousness or even death could occur. Don't run the engine when inside an enclosed area.

   1. Start engine.
   2. Set HVAC controls as follows:
      • RECIRCULATE
      • FULL HEAT
      • FRONT A/C FAN HIGH
      • REAR A/C FAN HIGH
      • A/C OFF
   3. Open one window approximately ".
   4. Let engine run for 10 minutes.

2. Remove glove box by:
   1. Pushing top stops inward.
   2. At right side hinge, lift clip out of its seat.
   3. Pull left axle pin out towards right side and remove glove box.

3. Remove dust filter cover located over fan assembly by depressing clip on inner side of cover.

4. Remove dust filter by pulling it out of filter housing. Discard filter if dirty.

5. Shake bottle of Mazda Air Cooling Coil Coating well and attach it to applicator. Then connect applicator to compressed shop air.

6. Insert the applicator into empty filter housing (approximately 41/4" from tip of applicator). Point nozzle tip downwards and towards the center (approximately 7 o'clock position).

7. Spray entire contents of bottle in short bursts, 3 seconds ON, 3 seconds OFF into the rotating fan. A fine mist may exit from the ducts.

   NOTE: If vehicle is equipped with rear a/c, skip STEP 8. Proceed to STEP 9.

8. When bottle is empty, stop engine and remove applicator. Let vehicle sit for 10 minutes.

   NOTE: For reuse, clean the applicator by flushing a bottle of clean water through it.

9. Install previously cleaned or new filter as needed and reinstall the filter cover

10. Reinstall glove box.

    2000-2003 MPV Rear AC (if equipped)

11. Remove right side cup holder.

12. Remove and disconnect rear fan control panel and convenience tray, if equipped.

13. Be sure HVAC controls are set per STEP 1B (see page 8).

    NOTE: Rear fan will operate even though rear fan control panel is disconnected.

14. Shake a new bottle of Mazda Air Cooling Coil Coating well and attach it to applicator. Then connect applicator to compressed shop air.

15. Begin inserting applicator through opening of control panel/convenience tray front to back with tip pointed up (for space). While inserting probe, rotate the tip outward toward fan air intake opening. When inserted (depth of insertion is approximately half length of applicator), point tip side center into cage without touching it.
16. Spray entire contents of bottle in short bursts, 3 seconds ON, 3 seconds OFF into rotating fan. A fine mist may exit from the ducts.

17. When bottle is empty, stop engine and remove applicator. Let vehicle sit for 10 minutes.

    NOTE: For reuse, clean the applicator by flushing a bottle of clean water through it.

18. Use STEP 1 to dry and cure product.

19. While the product is drying, re-install removed parts.

20. Note application date in service record.

1998 MPV Front A/C

1. Dry evaporator using the following procedure:

   WARNING: Running the engine inside an enclosed area, such as a garage, is dangerous. Exhaust gas, which contains poisonous carbon monoxide, could easily enter the cabin. Loss of consciousness or even death could occur. Don't run the engine when inside an enclosed area.

   1. Start engine.
   2. Set both front and rear (if applicable) HVAC controls as follows:
      • RECIRCULATE
      • FULL HEAT
      • FAN HIGH
      • A/C OFF
      • AIRFLOW (FACE & FLOOR)
   3. Open one window approximately ".
   4. Let engine run for 10 minutes to dry evaporator.

2. Remove glove box, removing side fascia plate on right door side.

3. Remove six (6) phillips screws to remove glove box assembly.

4. Shake well the bottle of Mazda Air Cooling Coil Coating and attach it to the applicator. Then connect applicator to compressed shop air.

5. Insert applicator into the grille of re-circulate door. Point nozzle tip down and towards center of cooling unit (approximately 7 o'clock position).

6. Spray entire contents of bottle in short bursts, 3 seconds ON, 3 seconds OFF into rotating fan. A fine mist may exit from ducts.

   NOTE: If vehicle is equipped with rear a/c, skip STEP 7. Proceed to STEP 8.

7. When bottle is empty, stop engine and remove applicator. Let vehicle sit for 10 minutes.

   NOTE: For reuse, clean the applicator by flushing a bottle of clean water through it.

   1998 MPV Rear A/C (if equipped)

8. Remove the four (4) screws holding down tailgate sill. Remove sill.

9. Remove one (1) screw holding down left inner panel. Lift complete panel out of clips.

10. Be sure HVAC controls are set per STEP 1B (see page 11).

11. Shake a new bottle of Mazda Air Cooling Coil Coating well and attach it to applicator. Then connect applicator to compressed shop air.

12. Position applicator with nozzle tip pointing down into air intake of fan motor.

13. Spray entire contents of bottle in short bursts, 3 seconds ON, 3 seconds OFF into rotating fan. A fine mist may exit from ducts.

14. When bottle is empty, stop engine and remove. Let vehicle sit for 10 minutes.

    NOTE: For reuse, clean the applicator by flushing a bottle of clean water through it.

15. Use STEP 1 to dry and cure product.

16. While product is drying, re-install removed parts.

17. Note application date in service record.

2001-2002 Millenia (with cabin air filter)

1. Dry evaporator using the following procedure:

   WARNING: Running the engine inside an enclosed area, such as a garage, is dangerous. Exhaust gas, which contains poisonous carbon monoxide, could easily enter the cabin. Loss of consciousness or even death could occur. Don't run the engine when inside an enclosed area.

   1. Start engine.
   2. Set HVAC controls as follows:
      • RECIRCULATE
      • FULL HEAT (display indicates 90°F)
      • FAN HIGH
      • A/C OFF (<blank>)
      • AIRFLOW (FACE)

        NOTE: There are three A/C positions on LCD panel (A/C, A/C econ, <blank>). Depress A/C button until <blank> is selected.

   3. Open one window approximately ".
   4. Let engine run for 10 minutes.

2. Remove lower panel by pulling downward at both ends.

3. Remove 10 mm nut retaining cabin air filter bracket.

4. Remove bracket by sliding downward.

5. Remove cabin air filters by sliding downward. Discard filters if dirty.

6. Cover cabin air filter access hole with duct tape.

7. Pierce hole in center of duct tape with knife.

8. Shake well the bottle of Mazda Cooling Coil Coating and attach it to applicator. Then connect applicator to compressed shop air.

9. Insert applicator in pierced hole through duct tape.

10. Point nozzle tip in the direction of driver's side.

11. Spray entire contents of bottle in short bursts, 3 seconds ON, 3 seconds OFF into rotating fan. A fine mist may exit from ducts.

12. When bottle is empty, stop engine and remove applicator. Let vehicle sit for 10 minutes.

    NOTE: For reuse, clean the applicator by flushing a bottle of clean water through it.

13. Use STEP 1 to dry and cure product.

14. Remove duct tape and install previously cleaned or new filters as needed.

15. Reinstall cabin air filter bracket.

16. Reinstall lower panel.

17. Note application date in service record.

1998-2000 Millenia

1. Dry evaporator using the following procedure:

   WARNING: Running the engine inside an enclosed area, such as a garage, is dangerous. Exhaust gas, which contains poisonous carbon monoxide, could easily enter the cabin. Loss of consciousness or even death could occur. Don't run the engine when inside an enclosed area.

   1. Start engine.
   2. Set HVAC controls as follows:
      • RECIRCULATE
      • FULL HEAT (display indicates 90°F)
      • FAN HIGH
      • A/C OFF (<blank>)
      • AIRFLOW (FACE)

        NOTE: There are three A/C positions on LCD panel (A/C, A/C econ, <blank>). Depress A/C button until <blank> is selected.

   3. Open one window approximately ".
   4. Let engine run for 10 minutes.

2. Remove glove box by removing two (2) screws on bottom of glove box assembly.

3. Shake well the bottle of Mazda Cooling Coil Coating and attach it to applicator. Then connect applicator to compressed shop air.

4. Insert applicator through the right side glove box guide into grille of recirculation door. Point nozzle tip downwards and towards the center (approximately 7 o'clock position).

5. Spray entire contents of bottle in short bursts, 3 seconds ON, 3 seconds OFF into rotating fan. A fine mist may exit from ducts.

6. When bottle is empty, stop engine and remove applicator. Let vehicle sit for 10 minutes.

   NOTE: For reuse, clean the applicator by flushing a bottle of clean water through it.

7. Use STEP 1 to dry and cure product.

8. While product is drying, re-install glove box.

9. Note application date in service record.

1999-2003 Miata

1. Dry the evaporator using the following procedure:

   WARNING: Running the engine inside an enclosed area, such as a garage, is dangerous. Exhaust gas, which contains poisonous carbon monoxide, could easily enter the cabin. Loss of consciousness or even death could occur. Don't run the engine when inside an enclosed area.

   1. Start engine.
   2. Set HVAC controls as follows:
      • Air source: re-circulate
      • Heater control: full heat
      • Fan: high
      • A/C switch: off
      • Airflow (Face)
   3. Open one window approximately ".
   4. Let engine run for 10 minutes.

2. Open glove box and remove by lifting the left side and pulling the right side in a downward direction.

3. Shake well the bottle of Mazda Cooling Coil Coating and attach it to applicator. Then connect applicator to compressed shop air.

4. Insert applicator in grille of the recirculation door. Point nozzle tip downwards and towards center (approximately 7 o'clock position).

5. Spray entire contents of bottle in short bursts, 3 seconds ON, 3 seconds OFF into rotating fan. A fine mist may exit from ducts.

6. When bottle is empty, stop engine and remove applicator. Let vehicle sit for 10 minutes.

   NOTE: Clean empty bottle by flushing it with clean water.

7. Use STEP 1 to dry and cure product.

8. While product is drying, re-install glove box.

9. Note application date in service record.