Engine Cooling System [Skyactiv-G 2.0]: Removal & Installation Mazda 3 BL рестайлинг

ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]

Note. If the "FL22" mark is shown on or near the cooling system cap, use Mazda Genuine FL22 engine coolant. (Scheme 42): Identifying FL22 Mark On Cooling System Cap FL22 type engine coolant is shipped as a diluted solution. Use the solution as is when replacing coolant. Engine coolant capacity (approx. quantity) MTX: 7.4 L {7.8 US qt, 6.5 lmp qt} ATX: 8.2 L {8.7 US qt, 7.2 lmp qt}

Scheme 41

Scheme 42

Scheme 43

1. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520419-S32364526322013010300000).)
2. Remove the air cleaner and air hose component. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520422-S09166380872013010300000).)
3. Loosen the radiator drain plug. (Scheme 43): Identifying Radiator Drain Plug CAUTION: Engine coolant drains out from the engine coolant outlet of the radiator while connecting the hose. To prevent the engine coolant from accumulating in aerodynamic undercover No.2, use rags to cover the area under the radiator drain plug and area around the service hole of aerodynamic undercover No.2 to absorb the engine coolant.
4. When the engine coolant starts draining, immediately connect an appropriate hose (25 mm {0.98 in} inner diameter) to the engine coolant outlet of the radiator and drain the engine coolant into the container with the hose passing though the hole of aerodynamic undercover No.2 as shown in the figure. (Scheme 44): Identifying Hose And Hole Of Aerodynamic Undercover No.2
5. Remove the cooling system cap. (Scheme 45): Identifying Cooling System Cap
6. Flush the cooling system with water until all traces of color are gone.
7. Let the system drain completely.
8. Remove the hose connected to the engine coolant outlet of the radiator.
9. Tighten the radiator drain plug. Tightening torque 1.2-1.5 N.m {13-15 kgf.cm, 11-13 in.lbf}
10. Referring to the following chart, select the correct volume percentage of the water and engine coolant. Antifreeze solution mixture percentage (Except FL22 type engine coolant) Engine 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
11. Refill the engine coolant into the coolant reserve tank up to the MAX mark on the tank.
12. Install the cooling system cap. CAUTION: If the high engine coolant temperature warning light flashes, stop the engine to lower the engine coolant temperature and 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.
13. Install the air cleaner and air hose component. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520422-S09166380872013010300000).)
14. Start the engine and warm up the engine by idling.
15. 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 PCM 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.
16. Stop the engine, and inspect the engine coolant level after the engine coolant temperature decreases.
17. Check the coolant level. If it is low, refill the coolant into the coolant reserve tank up to the MAX mark on the tank.
18. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 2.0]»(ref-520423-S16734547232013010300000).)
19. Install the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520419-S32364526322013010300000).)

Scheme 44

Scheme 45

1. Measure the engine coolant temperature and specific gravity using a thermometer and a hydrometer. CAUTION: Use 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 Mazda Genuine FL22 engine coolant. (Scheme 46): Identifying FL22 Mark On Cooling System Cap FL22 type engine coolant is shipped as a diluted solution. Use the solution as is when replacing coolant.
2. Determine the engine coolant protection level by referring to the graph shown in the figure. see scheme 9: Engine Coolant Protection Level Graph If the engine coolant protection level is not correct, add water or engine coolant.

RADIATOR DRAIN PLUG REPLACEMENT [SKYACTIV-G 2.0]

Scheme 46

1. Remove the aerodynamic under cover No.2. (See «AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-520448-S37186396192013010300000).)
2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-520423-S34603428342013010300000).)
3. Loosen the radiator drain plug completely.
4. Using a flathead screwdriver or equivalent, pry out the radiator drain plug. see scheme 10: Prying Out Radiator Drain Plug Using Flathead Screwdriver CAUTION: Do not apply excessive force to the flathead screwdriver or equivalent as doing so can damage the drain bore. Slowly and carefully pry out the radiator drain plug when removing it.
5. Install a new radiator drain plug. Tightening torque 1.2-1.5 N.m {13-15 kgf.cm, 11-13 in.lbf}
6. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-520423-S34603428342013010300000).)
7. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 2.0]»(ref-520423-S16734547232013010300000).)
8. Install the aerodynamic under cover No.2. (See «AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-520448-S37186396192013010300000).)

COOLANT RESERVE TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

Scheme 47

1. Drain the engine coolant until the coolant reserve tank becomes empty. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-520423-S34603428342013010300000).)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-520423-S34603428342013010300000).)
5. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 2.0]»(ref-520423-S16734547232013010300000).) (Scheme 49): Identifying Coolant Reserve Tank Removal Order

RADIATOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520427-S28538867222013010300000) .)
2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520427-S28538867222013010300000) .)
3. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520419-S32364526322013010300000) .)
4. Remove the fresh air duct (No.1, No.2), air cleaner and air hose component. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520422-S09166380872013010300000) .)
5. Remove the aerodynamic under cover No.2. (See «AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-520448-S37186396192013010300000) .)
6. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-520423-S34603428342013010300000) .)
7. Remove the cooling fan component. (See «COOLING FAN COMPONENT REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520423-S30348256262013010300000) .)
8. Remove in the order indicated in the table.
9. Install in the reverse order of removal.
10. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-520423-S34603428342013010300000) .)
11. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 2.0]»(ref-520423-S16734547232013010300000) .)

Identifying Radiator Removal Order. Scheme 48

Scheme 49

1. While pressing the radiator mount tab in the direction of the arrow shown in the figure, lift the radiator mount. (Scheme 50): Identifying Radiator Mount Tab Pressing Direction
2. Remove the radiator mount.

Scheme 50

1. Lift the radiator and remove it from the radiator installation holes on the shroud panel.
2. Move the radiator and condenser to the engine side.
3. Release the left and right tabs on the lower side of the radiator by pressing them in the direction shown in the figure. (Scheme 51): Identifying Left And Right Tabs On Lower Side Of Radiator
4. Lift the condenser to remove it from the left and right insertion areas on the upper side of the radiator. see scheme 17: Identifying Left And Right Insertion Areas On Upper Side Of Radiator
5. Set the condenser apart from the radiator.
6. Remove the radiator from below the engine compartment.

Scheme 51

1. Install the radiator mount so that the arrow on it is pointed toward the front of the vehicle. (Scheme 53): Identifying Radiator Mount Arrow Pointed Toward Front Of Vehicle

THERMOSTAT REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

1. Remove the battery, battery tray and PCM component. (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520427-S28538867222013010300000) .)
2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-520423-S34603428342013010300000) .)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-520423-S34603428342013010300000) .)
6. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 2.0]»(ref-520423-S16734547232013010300000) .)

Identifying Thermostat Removal Order With Torque Specifications. Scheme 52

Thermostat Cover Removal Note

1. Place rags on the transaxle case around the area under the thermostat cover.
2. Slightly loosen the three thermostat cover bolts and use the rags to absorb the draining engine coolant. CAUTION: Do not remove the thermostat cover completely at this time because the engine coolant remaining in the engine will drain out.
3. After the engine coolant stops draining, remove the thermostat cover.

Scheme 53

1. Install the thermostat with the jiggle pin aligned with the notch of the water outlet. see scheme 20: Aligning Thermostat Jiggle Pin With Notch Of Water Outlet

1. Install the thermostat cover while lifting it upward so that it does not contact the jiggle pin. (Scheme 55): Identifying Thermostat Cover

WATER PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

Note. Do not disassemble the water pump because it is a precision unit. Remove/install the water pump pulley and water pump from the underside of the vehicle.

1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520427-S28538867222013010300000) .)
2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520427-S28538867222013010300000) .)
3. Remove the aerodynamic under cover No.2 and splash shield as a single unit. (See «AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-520448-S37186396192013010300000) .)(See «SPLASH SHIELD REMOVAL/INSTALLATION»(ref-520448-S04813808932013010300000) .)
4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-520423-S34603428342013010300000) .)
5. Remove the water pump drive belt with the generator drive belt still installed and set it out of the way. (See «DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520419-S19266621512013010300000) .)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-520423-S34603428342013010300000) .)
9. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 2.0]»(ref-520423-S16734547232013010300000) .)

Identifying Water Pump Removal Order With Torque Specifications. Scheme 54

Water Pump Pulley Removal Note

Scheme 55

1. Align the water pump pulley hole with the water pump hole as shown in the figure. (Scheme 56): Aligning Water Pump Pulley Hole With Water Pump Hole
2. Insert an appropriate bolt (length 70 mm {2.8 in}) into the water pump hole shown in the figure and lock the water pump pulley against rotation. (Scheme 57): Locking Water Pump Pulley Against Rotation
3. Remove the bolt used for locking the water pump pulley against rotation.

Scheme 56

Scheme 57

1. Remove the water inlet pipe stay bolt. (Scheme 58): Identifying Water Inlet Pipe Stay Bolt
2. Place a container under the engine to collect the engine coolant remaining in the engine.
3. Slightly loosen the three water pump component bolts shown in the figure and collect the draining engine coolant into a container. (Scheme 59): Identifying Water Pump Component Bolts CAUTION: Do not remove the water pump component completely at this time because the remaining approx. 2 L or less of engine coolant flowing in the engine will drain out.
4. After the engine coolant stops draining, remove the water pump component.

O-ring Installation Note

1. Apply engine coolant to a new O-ring.
2. Install the O-ring to the water inlet pipe.

Scheme 58

Scheme 59

1. Tighten the bolts in the order shown in the figure. (Scheme 60): Identifying Water Pump Bolts Tightening Order Tightening torque 20-26 N.m {2.1-2.6 kgf.m, 15-19 ft.lbf}
2. Clean away the sealant adhering to the bolt hole on the cylinder block side of the water inlet pipe stay.
3. Install a new water inlet pipe stay bolt. (Scheme 61): Identifying Water Inlet Pipe Stay Bolt With Torque Specifications

Water Pump Pulley Installation Note

Scheme 60

Scheme 61

1. Install the water pump pulley to the water pump and temporarily tighten the bolt
2. Align the water pump pulley hole with the water pump hole as shown in the figure. see scheme 29: Aligning Water Pump Pulley Hole With Water Pump Hole
3. Insert an appropriate bolt (length 70 mm {2.8 in}) into the water pump hole shown in the figure and lock the water pump pulley against rotation. (Scheme 63): Locking Water Pump Pulley Against Rotation
4. Completely tighten the water pump pulley bolt to the specified torque. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
5. Remove the bolt used for locking the water pump pulley against rotation.

COOLING FAN COMPONENT REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520427-S28538867222013010300000) .)
2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520427-S28538867222013010300000) .)
3. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520419-S32364526322013010300000) .)
4. Remove the fresh air duct (No.1, No.2), air cleaner and air hose component. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-520422-S09166380872013010300000) .)
5. Remove the aerodynamic under cover No.2. (See «AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-520448-S37186396192013010300000) .)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.

Identifying Cooling Fan Component Removal Order. Scheme 62

Scheme 63

Scheme 64

Scheme 65

1. Remove the lower radiator hose from the lower radiator hose clip. (Scheme 64): Identifying Lower Radiator Hose And Lower Radiator Hose Clip
2. Remove the upper radiator hose from the upper radiator hose clip. (Scheme 65): Identifying Upper Radiator Hose And Upper Radiator Hose Clip
3. Release the left and right tabs on the lower side of the radiator by pressing them in the direction shown in the figure. see scheme 34: Identifying Left And Right Tabs On Lower Side Of Radiator
4. Lift the cooling fan component to remove it from the left and right insertion areas on the upper side of the radiator. see scheme 35: Identifying Left And Right Insertion Areas On Upper Side Of Radiator
5. Remove the cooling fan component from below the engine compartment.