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Cooling System (L3): Removal & Installation Mazda 5 I

Cooling System (Mechanical) 15 illustrations ~1336 words

ENGINE COOLANT REPLACEMENT [L3]

WARNINGNever remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine 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 to the first stop. Step back while the pressure escapes. When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, 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)

7.0 L {7.4 US qt, 6.2 Imp qt}

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7
  1. Remove the coolant reserve tank with the hose still connected.
  2. Remove the coolant reserve tank cap and drain the engine coolant from the coolant reserve tank.
  3. Remove the cooling system cap.
  4. Remove the battery duct. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
  5. Loosen the radiator drain plug and drain the engine coolant into a container.
  6. Flush the cooling system with water until all traces of color are gone.
  7. Let the system drain completely.
  8. Tighten the radiator drain plug.
  9. Referring to the following chart, select the correct volume percentage of the water and coolant. Antifreeze solution mixture percentage (Except FL22 type engine coolant) ENGINE COOLANT SPECIFICATION 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
  10. Refill the coolant from the cooling system filler neck until it is close to the top of the cooling system filler neck.
  11. Refill the coolant into the coolant reserve tank up to the F mark on the tank.
  12. 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.
  13. Start the engine and warm up the engine by idling.
  14. After the engine warms up, perform the following steps. At this time, be careful of the coolant temperature to prevent overheating. Run the engine at approx. 2,500 RPM for 5 min. Run the engine at approx. 3,000 RPM for 5 s, then idle. Repeat step (2) 4-5 times.
  15. Stop the engine, and inspect the coolant level after the coolant temperature decreases. If it is low, repeat steps 10 - 14 .
  16. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [L3]»(ref-244337-S28999413532006092100000) ).

COOLANT RESERVE TANK REMOVAL/INSTALLATION [L3]

WARNINGNever remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine 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 to the first stop. Step back while the pressure escapes. When you're sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

Scheme 8

Scheme 8
Scheme 8
  1. Remove in the order indicated in the table. COOLANT RESERVE TANK CHART 1 Hose 2 Coolant reserve tank
  2. Install in the reverse order of removal.

RADIATOR REMOVAL/INSTALLATION [L3]

WARNINGNever remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine 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 to the first stop. Step back while the pressure escapes. When you're sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

Scheme 9

Scheme 9
Scheme 9
  1. Remove the battery cover and battery duct. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
  2. Disconnect the negative battery cable.
  3. Remove the under cover.
  4. Remove the cooling fan component. (See «FAN MOTOR REMOVAL/INSTALLATION [L3]»(ref-244337-S04115688722006092100000) ).
  5. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [L3]»(ref-244337-S29195014592006092100000) ).
  6. Remove the air cleaner. (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION [L3]»(ref-244332-S08851886592006092100000) ).
  7. Remove the front bumper. (See «FRONT BUMPER REMOVAL/INSTALLATION»(ref-244342-S11707177962006092100000) ).
  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 [L3]»(ref-244337-S29195014592006092100000) ).
  11. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [L3]»(ref-244337-S28999413532006092100000) ). RADIATOR COMPONENT CHART 1 Radiator lower hose 2 Radiator upper hose 3 Upper mount rubber bracket (See «UPPER MOUNT RUBBER BRACKET REMOVAL NOTE»(ref-244337-S22752098802006092100000) ). 4 Upper mount rubber 5 Cooling system filler neck 6 Radiator (See «RADIATOR REMOVAL NOTE»(ref-244337-S29843663112006092100000) ). (See «RADIATOR INSTALLATION NOTE»(ref-244337-S34793605812006092100000) ).

Scheme 10

Scheme 10: Upper Mount Rubber Bracket Removal Note
Scheme 10: Upper Mount Rubber Bracket Removal Note
  1. Remove the upper mount rubber bracket while pressing down the upper mount rubber bracket tab in the direction of the arrow.

Scheme 11

Scheme 11: Radiator Removal Note
Scheme 11: Radiator Removal Note

Scheme 12

Scheme 12
Scheme 12
  1. Tilt the radiator to the engine side.
  2. While lifting the radiator, remove the lower mount rubber (LH) from the mount installation hole.
  3. While lifting the radiator, remove the lower mount rubber (RH) from the mount installation hole.
  4. Remove the condenser from the radiator with the pipes still connected, by pressing the radiator side tab to unlock the tab C on the condenser.
  5. Remove the radiator from below.

Scheme 13

Scheme 13: Radiator Installation Note
Scheme 13: Radiator Installation Note
  1. Install the condenser to the radiator by aligning lower side tab C with the radiator side tab, install upper tab C, then install lower side tab C.

THERMOSTAT REMOVAL/INSTALLATION [L3]

WARNINGNever remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine 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 to the first stop. Step back while the pressure escapes. When you're sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

Scheme 14

Scheme 14
Scheme 14
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
  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 [L3]»(ref-244337-S29195014592006092100000) ).
  5. Position the coolant reserve tank out of the way.
  6. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [L3]»(ref-244325-S01662276622006092100000) ).
  7. Position the drive belt out of the way. (See «DRIVE BELT REPLACEMENT [L3]»(ref-244325-S01328208652006092100000) ).
  8. Remove the drive belt tensioner. (See «TIMING CHAIN REMOVAL/INSTALLATION [L3]»(ref-244325-S02860110252006092100000) ).
  9. Remove in the order indicated in the table.
  10. Install in the reverse order of removal.
  11. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [L3]»(ref-244337-S29195014592006092100000) ).
  12. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [L3]»(ref-244337-S28999413532006092100000) ). THERMOSTAT COMPONENT CHART 1 Bypass hose 2 Lower radiator hose 3 Thermostat component 4 Gasket

WATER PUMP REMOVAL/INSTALLATION [L3]

WARNINGNever remove the cooling system cap or loosen the radiator drain plug while the engine Is running, or when the engine and radiator are hot. Scalding engine 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 to the first stop. Step back while the pressure escapes. When you're sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

Scheme 15

Scheme 15
Scheme 15
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
  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 [L3]»(ref-244337-S29195014592006092100000) ).
  5. Position the coolant reserve tank out of the way.
  6. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [L3]»(ref-244325-S01662276622006092100000) ).
  7. Loosen the water pump pulley bolt and position the drive belt out of the way. (See «DRIVE BELT REPLACEMENT [L3]»(ref-244325-S01328208652006092100000) ).
  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 [L3]»(ref-244337-S29195014592006092100000) ).
  11. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [L3]»(ref-244337-S28999413532006092100000) ). WATER PUMP COMPONENT CHART 1 Water pump pulley 2 Water pump 3 O-ring

FAN MOTOR REMOVAL/INSTALLATION [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 and battery duct. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
  2. Disconnect the negative battery cable.
  3. Remove the under cover.
  4. Remove in the order indicated in the table. FAN MOTOR COMPONENT CHART 1 Fan control module connector 2 Cooling fan component (See «COOLING FAN COMPONENT REMOVAL NOTE»(ref-244337-S10688025832006092100000) ). (See «COOLING FAN COMPONENT INSTALLATION NOTE»(ref-244337-S16250254782006092100000) ). 3 Fan control module 4 Cooling fan 5 Cooling fan motor 6 Radiator cowling
  5. Install in the reverse order of removal.

Scheme 17

Scheme 17: Cooling Fan Component Removal Note
Scheme 17: Cooling Fan Component Removal Note

Scheme 18

Scheme 18
Scheme 18
  1. Release the left and right tabs on the upper side of the radiator by pressing them in the direction shown in the figure.
  2. Lift the cooling fan component to remove it from the left and right insertion areas on the lower side of the radiator.
  3. Remove the cooling fan component from below.

Cooling Fan Component Installation Note

  1. Insert the cooling fan component in the left and right insertion areas on the lower side of the radiator, and then attach the left and right tabs on the upper side of the radiator.

Scheme 19

Scheme 19: Part Inspection
Scheme 19: Part Inspection
  1. Verify that the battery is fully charged.
  2. Install a tester and battery to the cooling fan motor connector (2 terminals) as shown in the figure.
  3. Verify that fan motor operates smoothly at the standard current. If there is any malfunction, replace the applicable part. Cooling fan motor current 17-23 A

Scheme 20

Scheme 20: FAN CONTROL MODULE INSPECTION [L3]
Scheme 20: FAN CONTROL MODULE INSPECTION [L3]
  1. Start and warm up the engine.
  2. Monitor the engine coolant temperature with the WDS or the equivalent.
  3. Measure the voltage at terminal A of the fan control module connector (2 terminals) from the harness side as shown in the table. ENGINE COOLANT TEMPERATURE SPECIFICATION Inspection Result Condition A/C Engine coolant temp. IG SW ON OFF 95 °C {203 °F} or less 0 V (Fan stops). IG SW ON (Idling) OFF 95 °C {203 °F} or less 0 V (Fan stops). IG SW ON (Idling) ON (1) 95 °C {203 °F} or less 8.9-10.3 V IG SW ON (Idling) OFF 100 °C {212 °F} or more 4.1-14.6 V (1) Refrigerant pressure switch (middle) is on. If not within the specification, inspect the input signals from the following parts. Crankshaft Position (CKP) sensor Engine Coolant Temperature (ECT) sensor Throttle Position (TP) sensor Refrigerant pressure switch (middle)
  4. If all the above parts are normal, replace the fan control module.

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