Cooling System: Removal & Installation Mazda 6 GG

ENGINE COOLANT REPLACEMENT

Scheme 22

Scheme 23

1. Remove the cooling system cap and the radiator drain plug.
2. Drain the coolant into a container.
3. Flush the cooling system with water until all traces of color are gone.
4. Let the system drain completely.
5. Tighten the radiator drain plug. CAUTION: The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. Do not use alcohol or methanol in the cooling system. Use only ethylene-glycol-based coolant. Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will reduce the coolant's effectiveness. Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.
6. Referring to (Scheme 23), select proper volume percentage of the water and coolant. Antifreeze solution mixture percentage
7. Slowly pour the coolant into the radiator up to the coolant filler port. (L3 engine model)
8. Fill the engine coolant into the coolant reservoir tank up to the F mark on the coolant reservoir tank.
9. Tighten the cooling system cap. CAUTION: If the coolant temperature becomes too high, stop the engine to prevent it from overheating.
10. Start the engine and idle it until the cooling fan operates.
11. After engine warms up, perform the following steps. Run the engine at 2,500 rpm for 5 min. Run the engine at 3,000 rpm for 5 s, then idle. Repeat steps (2) several times. Idle the engine for 1 min.
12. Stop the engine and wait until it is cool.
13. Inspect the coolant level. If it is low, repeat Steps 7 - 12 (L3 engine model), Steps 8 - 12 (AJ engine model).
14. Install the cooling system cap.
15. Inspect for coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION»(ref-193833-S22305945992005092600000).)

Scheme 24

1. Clean the cooling system cap and the sealed part.
2. Inspect the crack or turn over on the sealed part of the cooling system cap. If not as specified, replace the cooling system cap.
3. Fill the SST (L3 engine model), commercially available radiator cap tester (AJ engine model) with the water or the engine coolant to the full level and attach the cooling system cap to the SST (L3 engine model), radiator cap tester (AJ engine model).
4. Hold the cooling system cap downward and apply pressure gradually. Verify that the pressure become held for 10 s within the specification. If the pressure is not held stable within the specification, replace the cooling system cap. Pressure L3:113-142 kPa {1.15-1.44 kgf/cm 2 , 16.4-20.4 psi} AJ: 94-122 kPa {0.95-1.25 kgf/cm 2 , 13.6-17.7 psi}

Water Pump Installation Note (AJ)

1. Tighten the bolts to the specified torque, then tighten them further 85°-95°. Tightening torque 10 N.m {102 kgf.cm, 89 In-lbf}

Scheme 25

1. Disconnect the negative battery cable.
2. Remove the shroud panel. (See «SHROUD PANEL REMOVAL/INSTALLATION»(ref-193882-S05210848312005092600000).)
3. Remove the cooler pipe stay. (See «CONDENSER REMOVAL/INSTALLATION»(ref-193872-S30880930322005092600000).)
4. Remove the oil hose stay. (ATX)
5. Remove in the order indicated in (Scheme 25).
6. Install in the reverse order of removal.

Scheme 26

1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-193833-S33923677642005092600000).)
3. Remove the shroud panel. (See «SHROUD PANEL REMOVAL/INSTALLATION»(ref-193882-S05210848312005092600000).)
4. Remove the cooler pipe stay. (See «CONDENSER REMOVAL/INSTALLATION»(ref-193872-S30880930322005092600000).)
5. Remove the oil hose stay. (ATX)
6. Disconnect the coolant reservoir hose from the radiator.
7. Remove in the order indicated in (Scheme 26).
8. Install in the reverse order of removal.
9. Add the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-193833-S33923677642005092600000).)

Scheme 27

Scheme 28

Scheme 29

1. Verify that the battery is fully charged.
2. Connect the battery positive voltage and an ammeter to the fan motor connector.
3. Verify that the fan motor operates smoothly at the standard current draw. If not as specified, replace the fan motor. Standard current [12 V] 8.5-11.5 (A) High (Cooling fan motor No.1 and No.2) Middle (Cooling fan motor No.2) Low (Cooling fan motor No.1 and No.2)

Scheme 30

1. Verify that the battery is fully charged.
2. Disconnect the fan control module connector (3 terminals).
3. Connect the positive battery voltage and an ammeter to the fan control module connector on fan motor side. (2 terminals)
4. Verify that the fan motor operates smoothly at the standard current draw. If not as specified, replace the fan motor.
5. Perform the same procedure as Step 2 for the cooling fan motor No.2. Standard current [12 V] 11.8-14.8 (A)

Scheme 31

Scheme 32

1. Remove the two bolts from the fan control module with the connectors still connected.
2. Start and warm up the engine.
3. Monitor the engine coolant temperature with the WDS or equivalent.
4. Measure the voltage at the terminal B of fan control module connector (2 terminals) (Scheme 31) If not as specified, replace the fan control module.