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Cooling System: Removal & Installation Mazda 3 BK

Cooling System (Mechanical) 17 illustrations ~820 words

ENGINE COOLANT REPLACEMENT

WARNINGRemove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise 2.5 turns. Step back while the pressure escapes. When you are sure all the pressure is gone, turn the cap using the cloth, and remove it.
CAUTIONUse engine coolant at a concentration that meets the environmental conditions in which the vehicle is driven, otherwise engine damage could occur. The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. Do not use alcohol or methanol in the cooling system. Use only ethylene-glycol-based coolant. Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will reduce the coolant's effectiveness. Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.

Scheme 7

Scheme 7
Scheme 7

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Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9
  1. Remove the cooling system cap.
  2. Remove the under cover.
  3. Remove the radiator drain plug and drain the engine coolant into a container.
  4. Flush the cooling system with water until all traces of color are gone.
  5. Let the system drain completely.
  6. Tighten the radiator drain plug. Tightening Torque 1.2-1.5 N.m {13-15 kgf.cm, 11-13 in.lbf}
  7. Referring to the following chart, select proper volume percentage of the water and coolant. Antifreeze Solution Mixture Percentage
  8. Refill the coolant into the coolant reserve tank up to the MAX mark on the tank.
  9. Fully install the cooling system cap.
  10. Start the engine and idle it until the thermometer indicator is in the center when the engine is at below 1,500 RPM .
  11. After the engine warms up, perform the following steps verifying that engine coolant temperature does not increase too high using the thermometer. Run the engine at 2,500 RPM for 5 min . Run the engine at 3,000 RPM for 5 s , then idle. Repeat Step 1 , 2 approx. two times.
  12. Stop the engine and wait until the coolant temperature decreases.
  13. Check the coolant level. If It is low, refill the coolant into the coolant reserve tank up to the MAX mark on the tank.
  14. Inspect for coolant leakage. If the coolant leaks, specify the malfunctioning part and repair or replace it.

COOLANT RESERVE TANK REMOVAL/INSTALLATION

WARNINGRemove and install all part when the engine is cold, otherwise they can cause severe burns or serious injury.

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11
  1. Drain the engine coolant until the coolant reserve tank becomes empty. (See «ENGINE COOLANT REPLACEMENT»(ref-177562-S03658227892005060200000) .)
  2. Remove in the order indicated in the figure.
  3. Install in the reverse order of removal.
  4. Add engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-177562-S03658227892005060200000) .)
  5. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION»(ref-177562-S15634761872005060200000) .)
WARNINGNever remove the cooling system cap while the engine is running, or when the engine and radiator are hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise 2.5 turns. Step back while the pressure escapes. When you're sure all the pressure is gone, turn the cap using the cloth, and remove it.

Scheme 12

Scheme 12
Scheme 12
  1. Clean the cooling system cap and the sealed part.
  2. Inspect the crack or turn over on the sealed part of the cooling system cap. If there is malfunction, replace the cooling system cap.
  3. Attach the cooling system cap to the radiator cap tester.
  4. Hold the cooling system cap downward and apply pressure gradually. Verify that the pressure holds for 10 s . If the pressure is not held stable within the specification, replace the cooling system cap. Pressure 135-155 kPa {1.38-1.58 kgf/cm 2 , 19.6-22.4 psi}

RADIATOR REMOVAL/INSTALLATION

WARNINGRemove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

Scheme 13

Scheme 13
Scheme 13

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Scheme 14
  1. Remove the battery cover.
  2. Disconnect the negative battery cable.
  3. Remove the under cover.
  4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-177562-S03658227892005060200000) .)
  5. Disconnect the coolant reservoir hose from the radiator.
  6. Position the front wiring harnesses out of the way.
  7. Remove in the order indicated in the figure.
  8. Install the reverse order or removal.
  9. Add engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-177562-S03658227892005060200000) .)
  10. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION»(ref-177562-S15634761872005060200000) .)

Scheme 15

Scheme 15: COOLING FAN COMPONENT REMOVAL NOTE
Scheme 15: COOLING FAN COMPONENT REMOVAL NOTE
  1. Unlock the lower side tab a at two points by pressing the cooling fan side tab, remove the upper side tab a at two points, then remove the cooling fan component from the radiator.

Scheme 16

Scheme 16: RADIATOR REMOVAL NOTE
Scheme 16: RADIATOR REMOVAL NOTE

Scheme 17

Scheme 17
Scheme 17
  1. Remove the condenser from the radiator with the pipes still connected, by pressing the radiator side tab to unlock tab b on the condenser.
  2. Remove rubber mount A from the mount installation hole.
  3. Tilt the radiator to the engine side.
  4. Remove rubber mount B from the mount installation hole.
  5. Remove the radiator from below.

Scheme 18

Scheme 18: RADIATOR INSTALLATION NOTE
Scheme 18: RADIATOR INSTALLATION NOTE
  1. Install the condenser to the radiator by aligning lower side tab b with the radiator side tab, install upper tab b, then install lower side tab b.
  2. Install the radiator.

Scheme 19

Scheme 19: COOLING FAN COMPONENT INSTALLATION NOTE
Scheme 19: COOLING FAN COMPONENT INSTALLATION NOTE
  1. Insert tab a to the radiator to install the cooling fan component.

THERMOSTAT REMOVAL/INSTALLATION

WARNINGRemove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21
  1. Remove the battery cover.
  2. Disconnect the negative battery cable.
  3. Remove the under cover and splash shield as a single unit.
  4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-177562-S03658227892005060200000) .)
  5. Position the coolant reserve tank out of the way.
  6. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)
  7. Position the drive belt out of the way. (See DRIVE BELT REPLACEMENT .)
  8. Remove the drive belt tensioner. (See TIMING CHAIN REMOVAL/INSTALLATION .)
  9. Remove in the order indicated in the figures.
  10. Install in the reverse order of removal.
  11. Add engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-177562-S03658227892005060200000) .)
  12. Inspect for the engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION»(ref-177562-S15634761872005060200000) .)

WATER PUMP REMOVAL/INSTALLATION

WARNINGRemove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23
  1. Remove the battery cover.
  2. Disconnect the negative battery cable.
  3. Remove the under cover and splash shield as a single unit.
  4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-177562-S03658227892005060200000) .)
  5. Position the coolant reserve tank out of the way.
  6. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)
  7. Loosen the water pump pulley bolt and position the drive belt out of the way. (See DRIVE BELT REPLACEMENT .)
  8. Remove in the order indicated in the figures.
  9. Install in the reverse order of removal.
  10. Add engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-177562-S03658227892005060200000) .)
  11. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION»(ref-177562-S15634761872005060200000) .)

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