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Cooling System (Lf, L3): Removal & Installation Mazda 3 BL

Cooling System (Mechanical) 10 illustrations ~979 words

ENGINE COOLANT REPLACEMENT [LF, L3]

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 and must be protected by an ethylene-glycol-based coolant to prevent corrosion and freezing. Do not use coolants containing Alcohol, Methanol, Borate or Silicate. These coolants could damage the cooling system. Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut down on the coolant's effectiveness. Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.

Note. If the "FL22" mark is shown on or near the cooling system cap, use FL22 type engine coolant. FL22 type engine coolant is shipped as a diluted solution (55% coolant, 45% water). Use the solution as is when replacing coolant. Engine coolant capacity (approx. quantity) 7.5 L {7.9 US qt, 6.6 lmp quantity}

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8
  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 the correct volume percentage of the water and coolant. Antifreeze solution mixture percentage VOLUME PERCENTAGE Coolant protection Volume percentage Gravity at 20°C {68°F} Water Coolant Above-16°C{3°F} 65 35 1.057 Above-26°C{-15°F} 55 45 1.072 Above-40°C{-40°F} 45 55 1.086
  8. Refill the coolant into the coolant reserve tank up to the MAX mark on the tank.
  9. Fully install the cooling system cap. CAUTION: If the water temperature gauge rises too high, stop the engine and decrease the water temperature to prevent overheating. Then, verify the malfunctioning part and repair or replace it. If the engine coolant level in the coolant reserve tank is below the MIN mark during engine coolant air bleeding operation, stop the engine, and after the engine coolant temperature decreases, add engine coolant. Then, resume the engine coolant air bleeding operation.
  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. Bleed the air by following the procedures below. At this time, be careful of the coolant temperature to prevent overheating. NOTE: If the accelerator pedal is depressed continuously for a specified time, the engine speed may decrease to the idle speed. This is due to the fuel cut control operation, which prevents overheating, and it does not indicate a malfunction. Run the engine at 2,500 rpm for 2-3 min, 2 times. Run the engine at 3,000 rpm for 5 s , then idle. Repeat steps 1 , 2 twice.
  12. Stop the engine, and inspect the coolant level after the coolant temperature decreases (water temperature gauge indicates 'C or less).
  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 engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [LF, L3]»(ref-345218-S37398212532009102000000) ).

COOLANT RESERVE TANK REMOVAL/INSTALLATION [LF, L3]

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

Scheme 9

Scheme 9
Scheme 9
  1. Drain the engine coolant until the coolant reserve tank becomes empty. (See «ENGINE COOLANT REPLACEMENT [LF, L3]»(ref-345218-S35273147202009102000000) ).
  2. Remove in the order indicated in the table.
  3. Install in the reverse order of removal.
  4. Add engine coolant. (See «ENGINE COOLANT REPLACEMENT [LF, L3]»(ref-345218-S35273147202009102000000) ).
  5. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [LF, L3]»(ref-345218-S37398212532009102000000) ).

RADIATOR REMOVAL/INSTALLATION [LF, L3]

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

Scheme 10

Scheme 10
Scheme 10
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
  2. Disconnect the negative battery cable.
  3. Remove the under cover.
  4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [LF, L3]»(ref-345218-S35273147202009102000000) ).
  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 table.
  8. Install in the reverse order of removal.
  9. Add engine coolant.(See «ENGINE COOLANT REPLACEMENT [LF, L3]»(ref-345218-S35273147202009102000000) ).
  10. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [LF, L3]»(ref-345218-S37398212532009102000000) ).

Scheme 11

Scheme 11: Cooling Fan Component Removal Note
Scheme 11: Cooling Fan Component Removal Note
  1. Unlock lower side tabs a at two points by pressing the cooling fan side tabs, remove upper side tabs a at two points, then remove the cooling fan component from the radiator.

Scheme 12

Scheme 12: Radiator Removal Note
Scheme 12: Radiator Removal Note

Scheme 13

Scheme 13
Scheme 13
  1. Remove the condenser from the radiator with the pipes still connected, by pressing the radiator side tabs to unlock tabs 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 14

Scheme 14: Radiator Installation Note
Scheme 14: Radiator Installation Note
  1. Install the condenser to the radiator by aligning lower side tabs b with the radiator side tabs, install upper tabs b, then install lower side tabs b.
  2. Install the radiator.

Cooling Fan Component Installation Note

  1. Insert tabs a to the radiator to install the cooling fan component.

THERMOSTAT REMOVAL/INSTALLATION [LF, L3]

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

Scheme 15

Scheme 15
Scheme 15
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
  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 [LF, L3]»(ref-345218-S35273147202009102000000) ).
  5. Position the coolant reserve tank out of the way.
  6. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [LF, L3]»(ref-345205-S31861420912009102000000) .)
  7. Position the drive belt out of the way. (See «DRIVE BELT REPLACEMENT [LF, L3]»(ref-345205-S18707332462009102000000) .)
  8. Remove the drive belt tensioner. (See «TIMING CHAIN REMOVAL/INSTALLATION [LF, L3]»(ref-345205-S28456323822009102000000) .)
  9. Remove in the order indicated in the table.
  10. Install in the reverse order of removal.
  11. Add engine coolant. (See «ENGINE COOLANT REPLACEMENT [LF, L3]»(ref-345218-S35273147202009102000000) ).
  12. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [LF, L3]»(ref-345218-S37398212532009102000000) ).

WATER PUMP REMOVAL/INSTALLATION [LF, L3]

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

Scheme 16

Scheme 16
Scheme 16
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF, L3]»(ref-345206-S36173522052009102000000) .)
  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 [LF, L3]»(ref-345218-S35273147202009102000000) ).
  5. Position the coolant reserve tank out of the way.
  6. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [LF, L3]»(ref-345205-S31861420912009102000000) .)
  7. Loosen the water pump pulley bolt and position the drive belt out of the way. (See «DRIVE BELT REPLACEMENT [LF, L3]»(ref-345205-S18707332462009102000000) .)
  8. Remove in the order indicated in the table.
  9. Install in the reverse order of removal.
  10. Add engine coolant. (See «ENGINE COOLANT REPLACEMENT [LF, L3]»(ref-345218-S35273147202009102000000) ).
  11. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [LF, L3]»(ref-345218-S37398212532009102000000) ).

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