Technical
Service Bulletin

Mazda North American Operations
Irvine, CA 92618-2922

Subject:
NO COOL AIR FROM AIR CONDITIONER (LEAK FROM
EVAPORATOR)

Bulletin No.: 07-005/19

Last Issued: 09/10/2019

BULLETIN NOTES
This bulletin supersedes the previously issued bulletin(s) listed below. The changes are noted below in Red.

Previously Issued TSBs: Date(s) Issued
07-002/17
01/13/2017
07-005/16
02/05/2016
07-002/15
01/28/2015
07-002/14
10/23/2014
APPLICABLE MODEL(S)/VINS
2013-2016 CX-5 vehicles with VINs lower than JM3KE******802941 (produced before April 7, 2016)
2014-2016 Mazda6 vehicles with VINs lower than JM1GJ******480633 (produced before April 7, 2016)
2014-2016 Mazda3 (Japan built) vehicles with VINs lower than JM1BM******346088 (produced before April
7, 2016)

DESCRIPTION
Some customers may complain about no cool air from the vents when the air conditioner (A/C) is ON. This
concern may be caused by A/C refrigerant leaking from the evaporator (A) at the joint between the tubes
(B) and the header (C) due to improper brazing (D). To correct the problem, the configuration of the header
has been changed to improve the brazing performance in this area.

Page 1 of 6
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2019 Mazda North American Operations, U.S.A.

Bulletin No.: 07-005/19

Last Issued: 09/10/2019

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

REPAIR PROCEDURE
1. Verify customer concern.
2. Verify that the level of A/C refrigerant charge is low (The A/C refrigerant high and low pressures are both
low).
3. Check for refrigerant leakage from any part of the system, using a colored dye.





If leakage is found from the A/C unit drain hose, check the A/C unit inside. If leakage is detected
from the evaporator, replace it with a modified one according to the instructions on MGSS online
(A/C UNIT DISASSEMBLY/ASSEMBLY).
NOTE: When replacing the evaporator, add approximately 40 ml {40 cc, 1.4 fl oz} of compressor oil
according to the instructions on MGSS online (A/C COMPRESSOR REMOVAL/INSTALLATION).
If leakage is found from other than evaporator, repair or replace it according to the instructions on
MGSS online.

4. Verify repair.

Page 2 of 6
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2019 Mazda North American Operations, U.S.A.

Bulletin No.: 07-005/19

Last Issued: 09/10/2019

PARTS INFORMATION
Part Number
GHP9-61J10A
D651-68-162A
9YA0-11-007
9YA0-11-003A
B455-32-099B
GHT2-32-099
KD31-32-099
9YA0-20-682
BBM4-61-J17

Description
Evaporator

Qty.
1

Notes
---

2
1
1
1
1
1
2
2

All models
Mazda6, Mazda3
CX-5
All models
Mazda6
Mazda3, CX-5
All models
All models

GJ6A-61-J19
GJ6E-61-J19
BP4K-61-242
5555-FG-002

Trim Clip
Bolt, Steering Wheel
Bolt, Steering Wheel
Bolt, Intermediate Shaft (Lower)
Bolt, Intermediate Shaft (Upper)
Bolt, Intermediate Shaft (Upper)
Bolt, Dashboard
O-Ring, Copper Pipe (Low) and Expansion
Valve
O-Ring, Copper Pipe (High)
O-Ring, Expansion Valve
Hose Clamp
A/ C Refrigerant

All models
All models
All models
---

ZZC0-61-K39

Compressor Oil (210 ml)

1
1
2
As
required
1

H760-61-K39

Compressor Oil (210 ml)

1

Mazda6 / CX-5:
1 compressor oil
repairs
5 vehicles (40 ml each)
Mazda3:
1 compressor oil
repairs
5 vehicles (40 ml each)

Page 3 of 6
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2019 Mazda North American Operations, U.S.A.

Bulletin No.: 07-005/19

Last Issued: 09/10/2019

Part Name

Description

Clip, Trim (A)

Bolt, Steering Wheel (A)

Bolt, Upper Intermediate Shaft (A)
Bolt, Lower Intermediate Shaft (B)

Bolt, Dashboard (A)

Page 4 of 6
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2019 Mazda North American Operations, U.S.A.

Bulletin No.: 07-005/19

Last Issued: 09/10/2019

Clip, Heater Hose (A)

O-Ring, Copper Pipe-Low (A)
O-Ring, Copper Pipe-High (B)

O-Ring, Expansion Valve (A)

Page 5 of 6
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2019 Mazda North American Operations, U.S.A.

Bulletin No.: 07-005/19

Last Issued: 09/10/2019

WARRANTY INFORMATION
NOTE:





This warranty information applies only to verified customer complaints on vehicles eligible for
warranty repair.
This repair will be covered under Mazda’s New Vehicle Limited Warranty.
Additional diagnostic time cannot be claimed for this repair.

Mazda3
Mazda6
CX-5
Warranty Type
A
A
A
Symptom Code
59
59
59
Damage Code
9G
9G
9G
Part Number Main ****-61-J10* (Evaporator) ****-61-J10* (Evaporator) ****-61-J10* (Evaporator)
Cause
Quantity
1
1
1
Related Part
5555-CP-OIL
5555-CP-OIL
5555-CP-OIL
Number
Quantity
7
4
4
(Qty. 7 = $7
(Qty. 4 = $4
(Qty. 4 = $4
Reimbursement)
Reimbursement)
Reimbursement)
XXK9RBRX (Evaporator
XXK9RBRX (Evaporator
XK9RBRX (Evaporator
replacement) /
replacement) /
replacement) /
Operation Number
3.1 Hrs.
3.1 Hrs.
3.2 Hrs.
/ Labor Hours:
XXK9RARX (Refrigerant
XXK9RARX (Refrigerant
XXK9RARX (Refrigerant
recharge two times) /
recharge two times) /
recharge two times) /
0.7 Hrs.
0.7 Hrs.
0.7 Hrs.
1st recharge for inspection 1st recharge for inspection 1st recharge for inspection
of gas leakage.
of gas leakage.
of gas leakage.
2nd recharge for after
2nd recharge for after
2nd recharge for after
evaporator replacement.
evaporator replacement.
evaporator replacement.
NOTE:





Claim the replacement parts as related parts.
Claim the compressor oil using 5555-CP-OIL, which will reimburse you for 1/5 of the can (1 can
repairs 5 vehicles).
Claim the A/C refrigerant by entering the applicable part number and the quantity used as related
part.

Page 6 of 6
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2019 Mazda North American Operations, U.S.A.