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Cooling System: Diagnosis Mazda 6 GG

Cooling System (Mechanical) 11 illustrations ~632 words

ENGINE COOLANT LEAKAGE INSPECTION

WARNINGNever remove the radiator 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 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.

Scheme 11

Scheme 11
Scheme 11
  1. Inspect the coolant level. (See «ENGINE COOLANT LEVEL INSPECTION»(ref-193833-S26074873252005092600000) .)
  2. Remove the cooling system cap.
  3. L3: Clean the mounting surface of the cooling system cap and the upper radiator hose. AJ: Clean the mounting surface of the cooling system cap.
  4. Connect the SST (L3 engine model), commercially available radiator cap tester (AJ engine model) to the coolant filler port.
  5. Apply specified pressure to the radiator. CAUTION: Applying more than 127 kPa {1.3 kgf/cm 2 , 18 psi} (L3 engine model), 107.9 kPa {1.1 kgf/cm 2 , 15.6 psi} (AJ engine model), can damage the hoses, fittings, and other components, and cause leaks. Pressure L3:127 kPa {1.3 kgf/cm 2 , 18 psi} AJ: 107.9 kPa {1.1 kgf/cm 2 , 15.6 psi}
  6. Verify that the pressure is held. If not as specified, inspect the system for coolant leakage. If the coolant leaks from the upper hose attachment part, replace the upper hose and the clamp. If the coolant leaks from the main body of the radiator (caulked part), replace the radiator.

Scheme 12

Scheme 12: RADIATOR REMOVAL/INSTALLATION
Scheme 12: RADIATOR REMOVAL/INSTALLATION
  1. Disconnect the negative battery cable.
  2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-193833-S33923677642005092600000).)
  3. Remove the air cleaner. (See L3: «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3]»(ref-180761-S28907503002005072800000), AJ: «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [AJ]»(ref-196915-S12790852492005101000000).)
  4. Remove the shroud panel. (See «SHROUD PANEL REMOVAL/INSTALLATION»(ref-193882-S05210848312005092600000).)
  5. Remove the cooling fan. (See «COOLING FAN REMOVAL/INSTALLATION»(ref-193833-S38854317312005092600000).)
  6. Disconnect the upper radiator hose from the radiator. (L3 engine model)
  7. Disconnect the oil hose from the radiator. (ATX)
  8. Remove the coolant reservoir hose. (AJ engine model)
  9. Remove in the order indicated in (Scheme 12).
  10. Install in the reverse order of the removal.
  11. Add the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-193833-S33923677642005092600000).)
  12. Inspect the engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION»(ref-193833-S22305945992005092600000).)

Scheme 13

Scheme 13: L3
Scheme 13: L3
  1. Disconnect the negative battery cable.
  2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-193833-S33923677642005092600000).)
  3. Remove the drive belt. (See «DRIVE BELT REPLACEMENT [L3]»(ref-193830-S25063981192005092600000).)
  4. Remove the P/S oil pump with hoses and pipe still connected. Position the P/S oil pump out of the way. (See «POWER STEERING OIL PUMP (L3) REMOVAL/INSTALLATION»(ref-193866-S40516715442005092600000).)
  5. Remove in the order indicated in (Scheme 13).
  6. Install in the reverse order of removal.
  7. Add the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-193833-S33923677642005092600000).)
  8. Inspect the engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION»(ref-193833-S22305945992005092600000).)

Scheme 14

Scheme 14: AJ
Scheme 14: AJ

Scheme 15

Scheme 15
Scheme 15
  1. Disconnect the negative battery cable.
  2. Remove the air cleaner. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [AJ]»(ref-196915-S12790852492005101000000).)
  3. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-193833-S33923677642005092600000).)
  4. Remove in the order indicated in (Scheme 14).
  5. Install in the reverse order of removal.
  6. Add the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-193833-S33923677642005092600000).)
  7. Inspect the engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION»(ref-193833-S22305945992005092600000).)

Scheme 16

Scheme 16: Thermostat Installation Note (AJ)
Scheme 16: Thermostat Installation Note (AJ)
  1. Install the thermostat into the thermostat case with the jiggle pin at the top.

Scheme 17

Scheme 17: THERMOSTAT INSPECTION
Scheme 17: THERMOSTAT INSPECTION

Scheme 18

Scheme 18
Scheme 18
  1. Visually inspect that the thermostat valve is closed.
  2. Place the thermostat and a thermometer in water. WARNING: During inspection, the thermostat and water are extremely hot and they can badly burn. Do not touch the thermostat and water directly.
  3. Heat the water and inspect the following. If not as specified, replace the thermostat.

Scheme 19

Scheme 19: L3
Scheme 19: L3
  1. Disconnect the negative battery cable.
  2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-193833-S33923677642005092600000).)
  3. Remove the drive belt. (See «DRIVE BELT REPLACEMENT [L3]»(ref-193830-S25063981192005092600000).)
  4. Remove in the order indicated in (Scheme 19).
  5. Install in the reverse order of removal.
  6. Add the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-193833-S33923677642005092600000).)

Scheme 20

Scheme 20: AJ
Scheme 20: AJ

Scheme 21

Scheme 21
Scheme 21
  1. Disconnect the negative battery cable.
  2. Remove the under cover.
  3. Remove the air cleaner. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [AJ]»(ref-196915-S12790852492005101000000).)
  4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-193833-S33923677642005092600000).)
  5. Remove the water pump drive belt pulley. (See «WATER PUMP DRIVE BELT PULLEY REMOVAL NOTE»(ref-193831-S26638521262005092600000).)
  6. Remove in the order indicated in (Scheme 20).
  7. Install in the reverse order of removal.
  8. Install the new water pump drive belt pulley. (See «WATER PUMP DRIVE BELT PULLEY INSTALLATION NOTE»(ref-193831-S12147829832005092600000).)
  9. Add the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-193833-S33923677642005092600000).)

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