2002 Mazda AC Problem

Your blower motor uses a lot of power so by turning it up you restrict power from all other circuits your charging system. Is most likely not functioning at its full productivity so - possibly altanator or battery try and see if it blows colder at idle or at highway speeds

I had to change out the the speed selector switch and connector pigtail - they were fried to a crisp. The resistor block was ok but the Blower Motor draws so many Amps (especially on high) that it was overheating the new pigtail and switch! New switch, new pigtail and new blower motor fixed my '03 Protege.

Thanks so from what both of you are have said it seems the problem is That the the blower motor is requesting more amps (power) then what it's getting so there for causing problems. Thanks but if I fix my charging system so the motor gets its full amp that its requesting then it will melt my connection so now I am woundering if theirs a less powerful blower motor that will fit my protege. That's what I need to look at next thanks

Wait but I was just thinking that blower never stops blowing even on a higher level its the compressor that is not engaging on level 2,3 and some times 4 almost as if its not getting the message to stay on for level 2,3,4 instead it turns its self off. I have anther question does the compressor have only one level off or on and blower motor the only one that speeds off or the compressor also have different levels?

There's a module that controls the compressor and fresh/recirculate modes. I found that the switch shorts out and drives the module bonkers. I don't know if it's feeding voltage back through something it isn't supposed to but I had the same weird symptoms. The compressor runs or it does not. The only control other than the manual button are under and over pressure switches on the pressure lines. In short: the compressor either engages or it does not whenever the module commands it. A fried switch will back feed into the module and cause it to do unexpected things. Have you pulled the switch to inspect the connector on the back? A blower motor is a blower motor, they just collect dirt and the bushings wear out over time. If you think about it - this one has lasted many years before it gave you trouble. A new one will probably last the remaining life of the car.

@Danson27 You may also be experiencing a blockage or damaged Evaporator or a blockage on the high side between your condenser, accumulator/dryer and orifice tube. This will cause the refrigerant to make it slowly to the evaporator inside the car.

So I added more free on and my ac stopped cooling for good because I over charged it. So then I replaced my condenser because it looked rough by doing this I drain the free on I then charged it back and it worked find in all settings now I just did this yesterday so I have to wait and see if the problem is for good or not. Thanks every one for the support.

Good deal Danson27, glad you are cool again. Hope thats it for the A/C troubles. Cheers.

Hi I need some help in have a 1996 mazda lantis it have in ac it's full I check it with gauges but the pump don't cut in when I turn it on but if I run the pump direct it blows cold how can I get it working with out running it direct I check and change the presure switch on the dryer bottle ?

This is due to an issue in the fan detection circuit. You can find an analysis of the issue and a suggested fix here: http://nikosapi.org/w/index.php/Mazda_Protege_Fan_Detection_ Circuit_Analysis I have implemented this on several Protege's and Protege5's and it works.

Hi mate I'm a fridgy you have the same problem I just experiencedon't with the same car that someone asked me to fix A/C for them. The gas and ac is charged and all good but the control circuit has issues. On all cars the compressor won't engage unless the fan is switched on. So power normally feeds ac switch from fan on switch then to ac relay. It will never be an alternator issue as suggested fans draws very little. What I would like to know if you changed the fan resistor, and if so did it fix your problem. I am thinking of ordering one. Pretty sure that is the issue. But obviously if it didn't work for u it won't for mine either. My fan only runs on the first speed but the ac only cuts in on all other fan speeds. So cold ac with no air. Or fan on speed 1 with no ac.

OK here is my story...similar to others...the switch acted wonky for years, finally gave out. I opened up the panel and found what others have found; the connector to the switch was melted and corroded. 1) I started simple; ordered a new switch (~$10). No dice - just got hot. 2) I looked for another connector on line and could not find one. This is a good thing because, as you will read, it is likely the connector would've melted again. 3) I went to the dealer and they told me that the resistor was shot. They also told me that a new harness, which would include the connector, which cost $1500. 4) I bought a new resistor (~$20) and created my own connector (see picture) for pennies, using 5 Female Quick Slide Terminals. All is well now. My guess is that the corroded resistor generated the heat that melted the connector.

Yep - 2001 protege LX - Fan worked in all settings but ac only in 1 and 4.. Tried replacing the resistor & switch, did not help.. Did the same thing as Springerrr - works perfectly..

After trying two new switches, I read this thread and followed the link suggested by @Rowe above: http://nikosapi.org/w/index.php/Mazda_Protege_Fan_Detection_ Circuit_Analysis. This lead to a brilliant analysis of the problem and a detailed illustrated fix procedure to follow. Basically, the problem is a circuit flaw that stems from age resistance appearing in the circuitry causing an over-voltage on the compressor clutch sensor line which then causes the sense circuit to think the blower fan is not running. This shuts down the compressor. It'll happen on fan speeds 3, 2 and finally 4 in the order of failure and starts with the flickering compressor light as the sense line starts receiving anything over 1.1V. The fix involved accessing the climate control wiring and attaching a resistance splitter which uses two resisters that get spliced into the sense line and also to ground--the instructions where very easy to follow once you get the climate control/radio dash panel off and cost less than $2 in parts. I think you'll find this is the one true fix for this problem. My thanks to nikosapi.org for what must have been a ton of work they did putting this info and fix procedure together!