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Engine Cooling System [Mzr 2.5]: Removal & Installation Mazda 6 GH рестайлинг

Cooling System (Mechanical) 11 illustrations ~1165 words

ENGINE COOLANT REPLACEMENT [MZR 2.5]

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 Mazda Genuine FL22 engine coolant. FL22 type engine coolant is shipped as a diluted solution. Use the solution as is when replacing coolant.

Engine coolant capacity (approx. quantity)

9.4 L {9.9 US qt, 8.3 imp qt}

Scheme 10

Scheme 10
Scheme 10
  1. Remove the cooling system cap.
  2. Loosen the radiator drain plug and drain the engine 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.
  6. 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) 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 {3.2 °F} 65 35 1.057 Above -26°C {-15 °F} 55 45 1.072 Above -40°C {-40 °F} 45 55 1.086
  7. Refill the engine coolant from the radiator filler neck until it is close to the top of the radiator filler neck.
  8. Refill the engine coolant into the coolant reserve tank up to the F mark on the tank.
  9. Install the cooling system cap. CAUTION: If the water temperature gauge rises too high, stop the engine and decrease the engine coolant temperature to prevent overheating. Then, verify the malfunctioning part and repair or replace it.
  10. Start the engine and warm up the engine by idling.
  11. 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 2,500 rpm for 5 min. Maintain the engine speed at 3,000 rpm for 5 s , and then idle. Repeat steps (2) several times.
  12. Stop the engine, and inspect the engine coolant level after the engine coolant temperature decreases. If it is low, repeat steps 7-11.
  13. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 2.5]»(ref-448580-S05051878482012012000000) .)

COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 2.5]

  1. Remove in the order indicated in the table.
  2. Install in the reverse order of removal.
1Wiring harness
2Hose
3Coolant reserve tank (See COOLANT RESERVE TANK REMOVAL NOTE .)

COOLANT RESERVE TANK COMPONENTS REMOVAL SEQUENCE

Scheme 11

Scheme 11
Scheme 11

Coolant Reserve Tank Removal Note

  1. Remove the coolant reserve tank from the radiator cowling tabs shown in the illustration by lifting them with a flathead screwdriver.

Scheme 12

Scheme 12
Scheme 12

RADIATOR REMOVAL/INSTALLATION [MZR 2.5]

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 fern are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.
  1. Disconnect the negative battery cable.
  2. Remove the aerodynamic undercover No 1. (See «AERODYNAMIC UNDER COVER NO. 1 REMOVAL/INSTALLATION»(ref-448621-S27173632662012012000000) .)
  3. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.5]»(ref-448580-S03220346392012012000000) .)
  4. Remove the air cleaner, air hose and fresh air duct component. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-448579-S21051015612012012000000) .)
  5. Remove the coolant reserve tank. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 2.5]»(ref-448580-S11651142292012012000000) .)
  6. Remove the cooling fan component. (See «COOLING FAN MOTOR REMOVAL/INSTALLATION [MZR 2.5]»(ref-448580-S07120384462012012000000) .)
  7. Disconnect the ATF oil cooler hose from the radiator. (ATX) (See «OIL COOLER REMOVAL/INSTALLATION [FS5A-EL]»(ref-448615-S21938466952012012000000) .)
  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 [MZR 2.5]»(ref-448580-S03220346392012012000000) .)
  11. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 2.5]»(ref-448580-S05051878482012012000000) .)
  12. Inspect the ATF level. (ATX) (See «AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION [FS5A-EL]»(ref-448615-S34844211352012012000000) .)

Scheme 13

Scheme 13
Scheme 13
1Lower radiator hose
2Upper mount rubber bracket (See UPPER MOUNT RUBBER BRACKET REMOVAL NOTE .)
3Upper mount rubber
4Radiator (See RADIATOR REMOVAL NOTE .) (See RADIATOR INSTALLATION NOTE .)

RADIATOR COMPONENTS REFERENCE CHART

Upper Mount Rubber Bracket Removal Note

CAUTIONTo present damage to the upper mount rubber bracket tab, do not apply excessive force.

Note. The upper mount rubber bracket can be easily removed fey pressing down the upper mount rubber bracket tab using one hand and pressing the notch area downward using the other hand.

  1. While pressing down the upper mount rubber bracket tab lightly in the direction of the arrow shown in the illustration, press the upper mount rubber bracket toward the vehicle front.
  2. Lift the front part of the upper mount rubber bracket and remove the upper mount rubber bracket.

Scheme 14

Scheme 14
Scheme 14

Radiator Removal Note

  1. Remove the four bolts which secure the condenser to the radiator and set the condenser apart from the radiator.
  2. Remove the radiator from above the engine compartment.

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16: Radiator Installation Note
Scheme 16: Radiator Installation Note
  1. Align the bracket groove of the condenser to the radiator positioning rib.
  2. Align the bracket notch of the condenser to the radiator positioning rib.
  3. Install the condenser installation bolts as shown in the illustration.

THERMOSTAT REMOVAL/INSTALLATION [MZR 2.5]

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, turn the cap using the cloth, and remove it.
  1. Disconnect the negative battery cable.
  2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.5]»(ref-448580-S03220346392012012000000) .)
  3. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.5]»(ref-448577-S27590243452012012000000) .)
  4. Remove the drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION [MZR 2.5]»(ref-448577-S01306009002012012000000) .)
  5. Remove the P/S oil pump with hose and pipe still connected. Position the P/S oil pump out of the way. (See «POWER STEERING OIL PUMP REMOVAL/INSTALLATION [MZR 2.5]»(ref-448619-S00793700942012012000000) .)
  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 [MZR 2.5]»(ref-448580-S03220346392012012000000) .)
  9. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 2.5]»(ref-448580-S05051878482012012000000) .)
1Water hose
2Lower radiator hose
3Thermostat component
4Gasket

THERMOSTAT COMPONENTS REMOVAL SEQUENCE

Scheme 17

Scheme 17
Scheme 17

WATER PUMP REMOVAL/INSTALLATION [MZR 2.5]

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, turn the cap using the cloth, and remove it.

Note. Coolant may have accumulated depending on how many years the water pump has been in use. However, this does not indicate a malfunction if the accumulated coolant does not cover the vapor escape hole.

  1. Disconnect the negative battery cable.
  2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.5]»(ref-448580-S03220346392012012000000) .)
  3. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.5]»(ref-448577-S27590243452012012000000) .)
  4. Loosen the water pump pulley bolts before removing the drive belt.
  5. Remove the drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION [MZR 2.5]»(ref-448577-S01306009002012012000000) .)
  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 [MZR 2.5]»(ref-448580-S03220346392012012000000) .)
  9. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 2.5]»(ref-448580-S05051878482012012000000) .)
1Water pump pulley
2Water pump
3O-ring (See O-RING INSTALLATION NOTE .)

WATER PUMP COMPONENTS REMOVAL SEQUENCE

Scheme 18

Scheme 18
Scheme 18

O-ring Installation Note

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

COOLING FAN MOTOR REMOVAL/INSTALLATION [MZR 2.5]

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.
  1. Disconnect the negative battery cable.
  2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.5]»(ref-448580-S03220346392012012000000) .)
  3. Remove the air cleaner, air hose and fresh air duct component. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-448579-S21051015612012012000000) .)
  4. Remove the coolant reserve tank. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 2.5]»(ref-448580-S11651142292012012000000) .)
  5. Remove in the order indicated in the table.
  6. Install in the reverse order of removal.
  7. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.5]»(ref-448580-S03220346392012012000000) .)
  8. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 2.5]»(ref-448580-S05051878482012012000000) .)

Scheme 19

Scheme 19
Scheme 19
1Air cleaner bracket
2Fan control module connector
3Wiring harness
4Upper radiator hose
5Water hose
6ATF oil cooler pipe (ATX) (See ATF OIL COOLER PIPE REMOVAL NOTE (ATX) .)
7Cooling fan component (See COOLING FAN COMPONENT REMOVAL NOTE .)
8Fan control module
9Cooling fan No. 1
10Cooling fan No. 2
11Cooling fan motor No. 1
12Cooling fan motor No. 2

COOLING FAN MOTOR COMPONENTS REFERENCE CHART

ATF Oil Cooler Pipe Removal Note (ATX)

  1. Remove the ATF oil cooler pipe with the hoses still connected. Position the ATF oil cooler pipe so that it is out of the way.

Cooling Fan Component Removal Note

  1. Remove the cooling fan component from above the engine compartment.

Scheme 20

Scheme 20
Scheme 20

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