.
Tightening torque when installing: 8.0 ± 1.1 ft·lb (10.8 ± 1.5 N·m)

c. Apply insulating tape

.

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d. Close the cover and apply insulating tape

.

e. Disconnect the connectors and apply insulating tape

.

7. Remove COVER HOSE
.
a. Loosen the hose clamps.
Tightening torque when installing: 2.2 ± 0.4 ft·lb (3.0 ± 0.5 N·m)

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8. Remove the BRKT-BAT.
a. Remove the bolts.
Tightening torque when installing: 6.8 ± 1.1 ft·lb (9.3 ± 1.5 N·m)

b. Remove the bolts.
Tightening torque when installing: 19.2 ± 3.2 ft·lb (26.0 ± 4.4 N·m)

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9. Remove the COVER ASSY-BAT.
a. Remove the bolts.
Tightening torque when installing: 8.0 ± 1.1 ft·lb (10.8 ± 1.5 N·m)

b. Remove the bolts
.
Tightening torque when installing: 6.8 ± 1.1 ft·lb (9.3 ± 1.5 N·m)

c. Remove the bolts.
Tightening torque when installing: 19.2 ± 3.2 ft·lb (26.0 ± 4.4 N·m)

10. With an assistant, remove the upper cover.

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11. Cover it with an insulating mat.
WARNING: The insulating mat must always cover parts other than the parts to be worked on.

COVER ASSY-BAT LEFT SIDE MOUNTING
1. Install it in reverse to the removal procedure
NOTE:
•
•
•
•

.

For the COVER ASSY-BAT, PLATE ASSY, replace the GASKET before installation.
Check that there are no foreign objects in the gasket grooves.
Insert the convex part of the gasket into the recess of COVER ASSY-BAT and insert it along the groove.
When assembling, it must be turned upside down and not assembled.

COVER ASSY-BAT

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PLATE ASSY

PLATE ASSY

COVER ASSY-BAT

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Follow the steps below to install the bolts.
a. Install and tighten the bolts in the following order: b1 - b20, b21, b22.
Tightening torque when installing: 19.2 ± 3.2 ft·lb (26.0 ± 4.4 N·m)

b. Retighten in order of b1 to b22.
c. Install the remaining bolts (in no particular order).
NOTE: Install the COVER HOSE.

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2. Perform an airtightness check.
a. Install SST (49JP-046A0).
b. Item 3 (GAGE SET) requires using two exsisting bolts from the battery
Tightening torque when installing: 8.0 ± 1.1 ft·lb (10.8 ± 1.5 N·m)

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49JP-046A0 LIB_AIR_TIGHT_TESTER_PHEV-2
No.

IMAGE

NAME

(1)

COUPLER A

(2)

COUPLER B

(3)

GAGE SET

b. Apply tape to prevent air from escaping (6)(7). On the red circle of the part, making sure it adheres properly
(Recommended: 3M 243J Plus 30mm or equivalent).

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c. Install the terminal cover and torque the bolts to specification, then install the service plug last for safety.

3. Install the COVER ASSY-BAT.
Follow the steps below to install the bolts.
a. Install the bolts in the following order:
• a → b → c → d (or a → b → d → c)

b. Tighten the bolts in the order of step a.
Tightening torque when installing: 8.0 ± 1.1 ft·lb (10.8 ± 1.5 N·m)
c. Connect the air pump to the SST and inject air of 0.29 psi (2.0kPa).
ATTENTION:
(1) DO NOT use compressor air from service shops as SST and driving batteries may be damaged.
(2) Using a hand pump, slowly pump air into the battery. You MUST take at least 2 minutes to reach 0.30 ro 0.31 psi (2.1
to 2.2 Kpa). Rapid injection will lead to damage to the gauge.
(3) For VENT-GAS ASSY ((8) in VIEW C above), DO NOT inject air over 0.4 psi (3.0 Kpa) because there is a risk that
the valve will open.
• If the valve is opened, replace VENT-GAS ASSY or PLATE ASSY because reuse is not possible when the valve
is opened.

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(4) Disconnect the air pump from the SST.
• If the SST and the air pump are connected, there is a risk that air will leak from the connection
(5) Adjust by pressing the valve so that it is 0.29 psi (2.0kPa).

c. Do an airtightness check.
After setting the internal pressure to 0.29 psi (2.0kPa), the gauge must maintain at least 0.28 psi (1.9 kPa) for 1 minute.
• If 0.28 psi (1.9 kPa) or more cannot be maintained, check the following:
1) Check the SST installation status.
2) Check the condition of gaskets set as non-reusable parts.
3) Check if COVER ASSY-BAT is damaged.
d. Remove the SST in reverse order to the installation procedure.

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PLUG ASSY-SERVICE REMOVAL
WARNING: If the following sign
is indicated in the procedure, high-voltage components (live parts with over 50V)
are involved. Make sure to take the necessary actions before servicing an electric vehicle, or you may get an electric
shock that can result in a serious injury or death in the worst case. Before servicing the electric vehicle, refer to the
(HIGH-VOLTAGE SERVICE CAUTIONS) in MGSS and make sure to take all necessary actions to start services This
repair can only be performed by properly trained technicians.

Items to be prepared

Target parts

Location (red part)

Part number

Location (red part)

[Non-reusable parts]

(1) KBB4-302K5
(2) KBB3-302K3
(3) KBB4-302K3
(4) KBB4-302K2

NOTE: When performing the procedure below, use only hand tools and calibrated torque wrenches for all internal work
and reassembly operations.
1. Remove the COVER ASSY-BAT

. See: COVER ASSY-BAT left side.

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2. Check the coverage area of the insulating mat

.

WARNING: The insulating mat must always cover parts other than the parts to be worked on.
*Red: parts to be worked on.

3. Remove the PLUG ASSY-SERVICE
a. Remove the connector.

.

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b. Open the cover

.

c. Remove the nuts
,
Tightening torque when installing: 6.8 ± 1.1 ft·lb (9.3 ± 1.5 N·m)

PLUG ASSY-SERVICE INSTALLATION
1. Install it in reverse to the removal procedure

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PARTS INFORMATION
Parts
Number

Description

Qty.

KR9P-614C0B

Compr, Eec-Drvn

1

KBB4-302J0

Box, Junction

1

0000-KTPHEV

PHEV Battery Removal
Replacement Parts Kit

1

Kit includes: 999461000 (4 Nuts), PE2340305 (2 Gaskets), GJ6E61J19
(1 O-ring No. 2), MH01302W3 (2 O-rings), and BBM461J17 (1 O-ring
Cooling unit).

0000-ACFUSE

AC Fuse Replacement
Parts Kit

1

Kit includes: KBB4302K5 (1 Gasket), KBB3302K3 (1 Gasket),
KBB4302K3 (1 Gasket), KBB4302K8 (1 Gasket), KBB4302K2 (1
Gasket)

Notes
Updated compressor is "B" level or greater.

NOTE: MASH authorization is required for all parts replacement except A/C compressor. Review Mazda
Warranty Policies and Procedures Policy No.:3.28 for details.
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 term, California Emission Warranty
(Long term) or Transitional Zero Emission Vehicle Warranty (2024-2025 MY).
• Additional diagnostic time cannot be claimed for this repair.
• This repair can only be performed by properly trained technicians.
Warranty Type

A

Symptom Code

59

Damage Code

9W

Part Number Main Cause
Quantity
Operation Number / Labor Hours:

KR9P-61-4C0B
1
XXX6TARX / 0.9 Hrs (Replace compressor)
XXX6TBRX / 3.8 Hrs (Replace compressor and junction
box)

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