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

Cooling System (Mechanical) 15 illustrations ~1347 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) 7.5 L {7.9 US qt, 6.6 lmp qt}

Identifying Cooling System Cap. Scheme 20

Scheme 20: Identifying Cooling System Cap
Scheme 20: Identifying Cooling System Cap

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22
  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-292887-S30644836642008080600000).) (Scheme 21): Identifying Cooling System Cap And Cooling System Filler Neck
  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. (Scheme 22): Identifying Radiator Drain Plug Antifreeze solution mixture percentage (Except FL22 type engine coolant) ANTIFREEZE SOLUTION MIXTURE PERCENTAGE 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 engine 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 approx. 5,000 rpm for 1 min. Run the engine at idle for 5 s. Repeat steps ( 1 ), ( 2 ) several 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-292898-S13877990332008080600000).)

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 23

Scheme 23
Scheme 23
  1. Remove in the order indicated in the table. (Scheme 23): Identifying Hose And 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 24

Scheme 24
Scheme 24
  1. Remove the battery cover and battery duct. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-292887-S30644836642008080600000).)
  2. Disconnect the negative battery cable.
  3. Remove the under cover.
  4. Remove the cooling fan component. (See «COOLING FAN COMPONENT REMOVAL/INSTALLATION [L3]»(ref-292898-S31061053762008080600000).)
  5. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [L3]»(ref-292898-S38953419202008080600000).)
  6. Remove the air cleaner. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3]»(ref-292889-S35789412952008080600000).)
  7. Remove the front bumper. (See «FRONT BUMPER REMOVAL/INSTALLATION»(ref-292918-S11216097782008080600000).)
  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-292898-S38953419202008080600000).)
  11. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [L3]»(ref-292898-S13877990332008080600000).) (Scheme 24): Identifying Radiator Remove/Install Components & Torque Specifications

Scheme 25

Scheme 25: Upper Mount Rubber Bracket Removal Note
Scheme 25: 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 25): Removing Upper Mount Rubber Bracket

Scheme 26

Scheme 26: Radiator Removal Note
Scheme 26: Radiator Removal Note

Scheme 27

Scheme 27
Scheme 27
  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. (Scheme 26): Identifying Lower Mount Rubbers
  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 27): Identifying Condenser And Condenser Tab

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. see scheme 15: Identifying Condenser

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 28

Scheme 28
Scheme 28
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-292887-S30644836642008080600000).)
  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-292898-S38953419202008080600000).)
  5. Position the coolant reserve tank out of the way.
  6. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [L3]»(ref-292896-S27251783132008080600000).)
  7. Position the drive belt out of the way. (See «DRIVE BELT REPLACEMENT [L3]»(ref-292896-S24012513952008080600000).)
  8. Remove the drive belt tensioner. (See «TIMING CHAIN REMOVAL/INSTALLATION [L3]»(ref-292896-S33762963882008080600000).)
  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-292898-S38953419202008080600000).)
  12. inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [L3]»(ref-292898-S13877990332008080600000).) (Scheme 28): Identifying Thermostat Remove/Install Components & Torque Specifications

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 are sure all the pressure is gone, press down on the cap using the cloth, turn ft, and remove it.

Scheme 29

Scheme 29
Scheme 29
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-292887-S30644836642008080600000).)
  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-292898-S38953419202008080600000).)
  5. Position the coolant reserve tank out of the way.
  6. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [L3]»(ref-292896-S27251783132008080600000).)
  7. Loosen the water pump pulley bolt and position the drive belt out of the way. (See «DRIVE BELT REPLACEMENT [L3]»(ref-292896-S24012513952008080600000).)
  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-292898-S38953419202008080600000).)
  11. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [L3]»(ref-292898-S13877990332008080600000).) (Scheme 29): Identifying Water Pump Remove/Install Components & Torque Specifications

O-ring Installation Note

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

COOLING FAN COMPONENT REMOVAL/INSTALLATION [L3]

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

Scheme 30

Scheme 30
Scheme 30
  1. Remove the battery cover and battery duct. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-292887-S30644836642008080600000).)
  2. Disconnect the negative battery cable.
  3. Remove the under cover.
  4. Remove in the order indicated in the table. (Scheme 30): Identifying Cooling Fan Remove/Install Components & Torque Specifications
  5. Install in the reverse order of removal.

Scheme 31

Scheme 31: Cooling Fan Component Removal Note
Scheme 31: Cooling Fan Component Removal Note

Scheme 32

Scheme 32
Scheme 32
  1. Release the left and right tabs on the upper side of the radiator by pressing them in the direction shown in the figure. (Scheme 31): Pressing Left And Right Tabs On Upper Side Of Radiator
  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. (Scheme 32): Lifting Cooling Fan Component

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 33

Scheme 33: Part Inspection
Scheme 33: 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 33): Identifying Cooling Fan Motor Connectors

Scheme 34

Scheme 34: FAN CONTROL MODULE INSPECTION [L3]
Scheme 34: FAN CONTROL MODULE INSPECTION [L3]
  1. Start and warm up the engine.
  2. Monitor the engine coolant temperature with the M-MDS.
  3. Measure the voltage between fan control module connector (2 terminals) terminals 2A and 2B from the harness side as shown in the table. (Scheme 34): Identifying Fan Control Module Connector Terminals ENGINE COOLANT TEMPERATURE AND VOLTAGE SPECIFICATION Inspection Result Condition A/C Engine coolant temp. IG SW ON or idling OFF 95 °C {203 °F} or less 0 V Idling ON (1) 95 °C {203 °F} or less 8.9-10.3 V 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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