TSB: 07-001/07

MULTI-MODEL - AIR CONDITIONING MUSTY / MILDEW ODOR

NOTE: This bulletin replaces 07-001/03. Please update your records accordingly.

BULLETIN NOTE

This bulletin supersedes 07-001/03 issued 05/02/2003. The APPLICABLE MODEL(S)/VINS and REPAIR PROCEDURE have been revised.

APPLICABLE MODEL(S)/VINS

• 2003-2007 Mazda6

• 2004-2007 Mazda3

• 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.

• Relatively clean and free of leaves, dust build-up and debris.

• 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, suggest the following to the customers:

• 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.

REPAIR PROCEDURE

1. Verify customer concern.

2. Verify the 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)
2003-2007 Mazda6	4-5
1998-2002 626	6-7
2004-2007 Mazda3	8-10
1998-2003 Protege & Protege5	11-12
2000-2003 MPV Front A/C	13-14
2000-2003 MPV Rear A/C	14
1998 MPV Front A/C	16-17
1998 MPV Rear A/C	17
2001-2002 Millenia	18-19
1998-2000 Millenia	20-21
1999-2003 Miata	22-23

NOTE:

• Follow the 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 the odor is still present after treatment, it may be necessary to remove and clean the evaporator, the evaporator foam, and the inside of the 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

WARRANTY INFORMATION

Note: This repair is not covered by warranty.

2003-2007 Mazda6

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 the engine.

2. Set the HVAC controls as follows.

• RECIRCULATE

• FULL HEAT

• FAN HIGH

• A/C OFF

• AIRFLOW (FACE)

  

3. Open one window approximately .

4. Let the engine run for 10 minutes.

2. Remove the glove box by:

1. Removing the damper clip.

   

2. Bending the stoppers inward to remove.

3. Opening the lid until it is completely horizontal and remove the lid by pulling it in the direction of the arrow.

   

3. Stop the engine. Switch OFF the fan motor.

4. Remove the cabin air filter cover, then the filter.

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

6. Insert the applicator through the the cabin air filter opening, then into the blower motor air intake opening. Point the nozzle tip downward and place it along the edge of the blower motor air intake opening.

7. Switch the fan motor ON.

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

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

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

10. Reinstall the cabin air filter.

11. Reinstall the glove box.

12. Use STEP 1 to dry and cure the product.

13. Note application date in service record.

1998-2002 626

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 the engine.

2. Set the HVAC controls as follows:

• RECIRCULATE

• FULL HEAT

• FAN HIGH

• A/C OFF

• AIRFLOW (FACE)

  

3. Open one window approximately .

4. Let the engine run for 20 minutes.

2. Remove the glove box by:

1. Pushing the top stops inward (plastic will flex).

   

2. At the right side hinge, lift the clip out of its seat.

3. Pull the left side axle pin out towards the right side and remove the glove box.

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

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

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

6. When the bottle is empty, stop the engine and remove the applicator. Let the 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 the product.

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

9. Note application date in service record.

2004-2007 Mazda3

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 the engine.

2. Set the HVAC controls as follows.

• RECIRCULATE

• FULL HEAT

• FAN HIGH

• A/C OFF

• AIRFLOW (FACE)

  

3. Open one window approximately .

4. Let the engine run for 10 minutes.

2. Stop the engine. Switch OFF the fan motor.

3. Record the radio preset stations.

4. Set the ignition to the LOCK position.

5. Disconnect the negative battery cable for 1 minute or more.

6. Remove the console sidewall on the passenger side footwell.

7. Remove the PJB and PJB bracket. Refer to appropriate Workshop Manual section 09-40 - PASSENGER JUNCTION BOX (PJB) REMOVAL/INSTALLATION.

NOTE: PJB module configuration does not need to be performed since the same module will be used.

8. Remove the metal bracket.

9. Disconnect the evaporator temperature sensor connector.

10. Disconnect the the Power MOS FET connector (full-auto climate control).

WARNING: Power MOS FET may be extremely hot.

11. Remove the cabin air filter cover, then remove the two cabin air filters.

12. Shake a bottle of the Mazda Air Cooling Coil Coating well and attach it to the applicator, then connect the applicator to compressed shop air.

13. Insert the applicator inside the hole. Point the nozzle tip in direction of the evaporator.

14. Begin spraying by gently moving the nozzle tip back and forth from the top to the bottom to evenly coat the evaporator.

15. When the bottle is empty, remove the applicator.

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

16. Reinstall the cabin air filters, then the cabin air filter cover.

17. Connect the Power MOS FET connector.

18. Connect the evaporator temperature sensor connector.

19. Reinstall the metal bracket.

20. Reinstall the PJB and PJB bracket. Refer to appropriate Workshop Manual section 09-40 - PASSENGER JUNCTION BOX (PJB) REMOVAL/INSTALLATION.

21. Reinstall the console side wall.

22. Use STEP 1 to dry and cure product.

23. 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 the engine.

2. Set the HVAC controls as follows.

• RECIRCULATE

• FULL HEAT

• FAN HIGH

• A/C OFF

• AIRFLOW (FACE)

  

3. Open one window approximately .

4. Let the engine run for 10 minutes.

2. Remove the glove box by:

1. Pushing the top stops inward (plastic will flex).

   

2. At the left side hinge, lift the clip out of its seat.

3. Pull the right axle pin out towards the left side and remove the glove box.

3. Stop the engine. Switch OFF the fan motor.

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

WARNING: Blower motor resistor may be extremely hot.

5. Reinstall the fan resistor.

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

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

8. Switch the fan motor ON.

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

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

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

11. Reinstall the glove box.

12. Use STEP 1 to dry and cure the product.

13. Note application date in service record.

2000-2003 MPV Front AC

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 the engine.

2. Set the 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 the engine run for 10 minutes.

2. Remove the glove box by:

1. Pushing the top stops inward.

2. At the right side hinge, lift the clip out of its seat.

3. Pull the left axle pin out towards the right side and remove the glove box.

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

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

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

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

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

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

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

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

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

10. Reinstall the glove box.

2000-2003 MPV Rear AC (if equipped)

11. Remove the right side cup holder.

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

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

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

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

15. Begin inserting the applicator through the opening of the control panel/convenience tray front to back with the tip pointed up (for space). While inserting the probe, rotate the tip outward toward the fan air intake opening. When inserted (depth of insertion is approximately half lthe ength of the applicator), point the tip side center into the cage without touching it.

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

17. When the bottle is empty, stop the engine and remove the applicator. Let the 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 the product.

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

20. Note application date in service record.

1998 MPV Front A/C

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 the 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 the engine run for 10 minutes.

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

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

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

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

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

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

7. When the bottle is empty, stop the engine and remove the applicator. Let the 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 the tailgate sill, then remove the sill.

9. Remove the one (1) screw holding down the left inner panel, then lift the complete panel out of the clips.

10. Be sure the 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 the applicator, then connect the applicator to compressed shop air.

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

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

14. When the bottle is empty, stop the engine and remove. Let the 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 the product is drying, re-install removed parts.

17. Note application date in service record.

2001-2002 Millenia (with cabin air filter)

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 the engine.

2. Set the 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 the LCD panel (A/C, A/C econ, blank). Depress the A/C button until blank is selected.

3. Open one window approximately .

4. Let the engine run for 10 minutes.

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

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

4. Remove the bracket by sliding downward.

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

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

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

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

9. Insert the applicator into the pierced hole through the duct tape.

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

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

12. When the bottle is empty, stop the engine and remove the applicator. Let the 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 the product.

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

15. Reinstall the cabin air filter bracket.

16. Reinstall the lower panel.

17. Note application date in service record.

1998-2000 Millenia

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 the engine.

2. Set the 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 the LCD panel (A/C, A/C econ, blank). Depress the A/C button until blank is selected.

3. Open one window approximately .

4. Let the engine run for 10 minutes.

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

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

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

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

6. When the bottle is empty, stop the engine and remove the applicator. Let the 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 the product.

8. While the product is drying, re-install the 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 the engine.

2. Set the 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 the engine run for 10 minutes.

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

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

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

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

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

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

7. Use STEP 1 to dry and cure the product.

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

9. Note application date in service record.