A/C - Fogging on Lower Exterior of Windshield
07-001/05 2003-2005 MAZDA6 - FOGGING ON LOWER EXTERIOR OF WINDSHIELDAPPLICABLE MODEL(S)/VINS
2003 - 2005 Mazda6 vehicles with Automatic or Manual Air Conditioning Systems
DESCRIPTION
In conditions of high humidity and high ambient temperatures, fogging may develop on the lower exterior portion of the front windshield. Fogging occurs when the A/C is on, and the dash, floor, or dash/floor vents airflow modes are selected. When these airflow modes are selected, small amounts of air may flow from the defroster vents. Fogging occurs when the temperature difference between the interior and exterior increases.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Set fan control dial to speed 3.
2. Set airflow mode selector to dash vents mode.
3. Place a sheet of 8-1/2" x 11" paper on center of dashboard over defroster vents
4. Turn ignition switch ON and observe paper.
^ If paper starts to flutter, proceed to Step 5 and perform repair procedures in this service bulletin.
^ If paper does not flutter, do not perform repair procedures in this service bulletin, refer to Workshop Manual (Section 07) for further troubleshooting.
5. Record customer's radio pre-set stations.
6. Move both front seats to most rearward position.
7. Fold both front seat backs backward (flat position).
8. Open glove compartment.
9. Remove glove compartment being careful not to break hinges (shown).
10. Remove damper clip string from right side of glove compartment.
11. Press both sides of glove compartment inward until it releases from dash.
12. Hold glove compartment in level position (not fully lowered).
NOTE:
Glove compartment will not come out if held too high or too low. When held level, glove compartment will come out easily.
13. Gently pull glove compartment toward you until hinges release.
14. For manual A/C systems, remove wire cable from pivot lever by depressing tabs.
NOTE:
To maintain same adjustment, place a reference mark between wire cable housing and retaining clip before removal.
15. Detach three (3) harness retaining clips.
16. Disconnect electrical connectors A - D.
17. Disconnect electrical connector and detach retaining clip from blower motor.
18. Loosen dashboard according to Workshop Manual (Section 09-17 DASHBOARD REMOVAL/INSTALLATION).
NOTE:
Keep the following points in mind when loosening/moving dashboard:
^ It is not necessary to completely remove dashboard from vehicle to access the top of the heater box.
^ It is not necessary to remove Center Panel Module or Center Box.
^ Before steering column removal, center steering wheel, then place reference marks on upper and lower steering column shafts for proper alignment during reassembly.
19. Remove four (4) steering column nuts.
20. Remove steering column.
21. After loosening dashboard assembly and disconnecting all necessary connectors, gently pull passenger side of dashboard away to access top of heater box.
22. Remove and discard Small Foam Seal from top/center of heater box.
NOTE:
DO NOT remove other foam seals around edges of heater box.
23. Remove and discard screen from top of heater box.
NOTE:
Screen is no longer needed and will not be replaced.
CAUTION:
Be careful not to allow screen material to fall into heater box during screen removal. During screen removal, some portions of foam seal (around edges) may pull away from heater box.
24. Firmly press down around entire foam seal to ensure a tight seal.
25. Completely clean area where Small Foam Seal was removed with isopropyl alcohol.
26. Allow alcohol to dry completely.
27. Peel off backing from new Small Foam Seal.
28. Adhere new Small Foam Seal onto top/center of heater box, pressing firmly to ensure a tight seal.
29. Reinstall dashboard according to Workshop Manual (Section 09-17 DASHBOARD REMOVAL/INSTALLATION).
NOTE:
Keep the following important points in mind during reinstallation:
^ After installing two (2) left side dash cover bolts, one (1) right side dash cover bolt, and both "A" pillar trim pieces, visually check that gaps at both ends of A pillars are equal. Shift dashboard assembly as required to obtain equal gaps.
^ On Manual A/C models, confirm wire cable is installed correctly.
^ Confirm reference marks on steering column shafts are aligned, and four (4) nuts are torqued to 11.6 - 16.5 ft-lbf.
^ When reinstalling shift knob on ATX and MTX models, do not exceed thirteen (13) complete turns. Additional turns may crack shift knob's inner plastic insulation.
^ On MTX V6 models, prior to reinstalling front console trim (with cigarette lighter), push cigarette lighter housing outward to allow clearance during reinstallation. To release cigarette lighter, use a small flat head screwdriver, move tab on plastic ring, then push lighter outward. After console trim is installed, push cigarette lighter inward until a "click" sound is heard.
30. Reinstall glove compartment in reverse order.
31. Perform Steps 1 - 4 again to verify repair. Ensure that air no longer flows from defroster vents.
32. Reset customer's pre-set radio stations.
PARTS INFORMATION
WARRANTY INFORMATION
NOTE:
^ This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the SRT microfiche for warranty term information.
^ Additional diagnostic time cannot be claimed for this repair.
Disclaimer