Engine Cooling System [Mzi 3.7 V6]: Removal & Installation Mazda 6 GJ

ENGINE COOLANT REPLACEMENT [MZI 3.7 V6]

Note. If the "FL22" mark is shown on or near the cooling system cap, use Mazda Genuine FL22 engine coolant. (Scheme 27): Identifying Coolant Reserve Tank F And L Marks FL22 type engine coolant is shipped as a diluted solution. Use the solution as is when replacing coolant.

Engine coolant capacity (approx. quantity)

1. 8.9 L {9.4 US qt, 7.8 Imp qt}

Scheme 26

Scheme 27

1. Remove the cooling system cap. (Scheme 28): Cooling System Cap
2. Loosen the radiator drain plug and drain the engine coolant into a container. (Scheme 29): Radiator Drain Plug
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) 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
7. Refill the engine coolant into the coolant reserve tank up to the F mark on the tank.
8. 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. If the engine coolant level in the coolant reserve tank is below the L mark during engine coolant air bleeding operation, stop the engine, and after the engine coolant temperature decreases, add engine coolant. Then, resume the engine coolant air bleeding operation.
9. Start the engine and warm up the engine by idling.
10. 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 does not indicate a malfunction. Run the engine at approx. 4,000 rpm for 1 min. Run the engine at idle for 1 min.
11. Stop the engine, and inspect the engine coolant level after the engine coolant temperature decreases. If it is low, repeat steps 7 - 10.
12. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZI 3.7 V6]»(ref-581683-S19761424272013101400000).)

Scheme 28

Scheme 29

1. Measure the engine coolant temperature and specific gravity using a thermometer and a hydrometer. CAUTION: Use 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. see scheme 7: Identifying Coolant Reserve Tank F And L Marks FL22 type engine coolant is shipped as a diluted solution. Use the solution as is when replacing coolant.
2. Determine the engine coolant protection level by referring to the graph shown in the figure. see scheme 8: Engine Coolant Protection Level Graph If the engine coolant protection level is not correct, add water or engine coolant.

COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZI 3.7 V6]

Scheme 30

1. Drain the engine coolant until the coolant reserve tank becomes empty. (See «ENGINE COOLANT REPLACEMENT [MZI 3.7 V6]»(ref-581683-S26168476562013101400000).)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZI 3.7 V6]»(ref-581683-S26168476562013101400000).)
5. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZI 3.7 V6]»(ref-581683-S19761424272013101400000).) (Scheme 32): Coolant Reserve Tank Components With Torque Specifications

RADIATOR REMOVAL/INSTALLATION [MZI 3.7 V6]

Scheme 31

1. Disconnect the negative battery cable.
2. Remove the aerodynamic under cover No.1. (See «AERODYNAMIC UNDER COVER NO.1 REMOVAL/INSTALLATION»(ref-581657-S31409051752013101400000).)
3. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZI 3.7 V6]»(ref-581683-S26168476562013101400000).)
4. Remove the air cleaner and fresh air duct component. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581679-S24618371532013101400000).)
5. Remove the cooling fan component. (See «COOLING FAN MOTOR REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581683-S04818170622013101400000).)
6. Disconnect the ATF oil cooler hose from the radiator. (See «OIL COOLER REMOVAL/INSTALLATION [AY6A-EL]»(ref-581676-S31177358192013101400000).)
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
9. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZI 3.7 V6]»(ref-581683-S26168476562013101400000).)
10. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZI 3.7 V6]»(ref-581683-S19761424272013101400000).)
11. Inspect the ATF level. (See «AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION [AY6A-EL]»(ref-581676-S07495707512013101400000).) (Scheme 33): Identifying Radiator Components

Upper Mount Rubber Bracket Removal Note

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

Scheme 32

1. While pressing down the upper mount rubber bracket tab lightly in the direction of the arrow shown in the figure, press the upper mount rubber bracket toward the vehicle front. (Scheme 34): Identifying Upper Mount Rubber Bracket Tab Pressing Direction
2. Lift the front part of the upper mount rubber bracket and remove the upper mount rubber bracket.

Scheme 33

1. Remove the four bolts which secure the condenser to the radiator and set the condenser apart from the radiator. (Scheme 35): Bolts Securing Condenser To Radiator With Torque Specifications
2. Remove the radiator from above the engine compartment.

Scheme 34

Scheme 35

Scheme 36

1. Align the bracket groove of the condenser to the radiator positioning rib. (Scheme 36): Aligning Bracket Groove Of Condenser To Radiator Positioning Rib
2. Align the bracket notch of the condenser to the radiator positioning rib. (Scheme 37): Aligning Bracket Notch Of Condenser To Radiator Positioning Rib
3. Install the condenser installation bolts as shown in the figure. (Scheme 38): Condenser Bolts With Torque Specifications

THERMOSTAT REMOVAL/INSTALLATION [MZI 3.7 V6]

Scheme 37

1. Disconnect the negative battery cable.
2. Remove the battery and battery tray. (See «BATTERY REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581639-S29135432412013101400000).)
3. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZI 3.7 V6]»(ref-581683-S26168476562013101400000).)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZI 3.7 V6]»(ref-581683-S26168476562013101400000).)
7. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZI 3.7 V6]»(ref-581683-S19761424272013101400000).) (Scheme 39): Thermostat Components With Torque Specifications

Scheme 38

1. Install the thermostat into the thermostat case with the jiggle-pin at the top. (Scheme 40): Thermostat With Jiggle-Pin At Top

O-ring Installation Note

1. Clean and inspect the O-ring. Install a new O-ring if necessary.
2. Apply clean engine coolant to the O-ring.
3. Install the O-ring.

WATER PUMP REMOVAL/INSTALLATION [MZI 3.7 V6]

Note. The following procedure "WATER PUMP REMOVAL/INSTALLATION" is performed after the engine and transaxle component is removed from the vehicle.

Scheme 39

Scheme 40

1. Drain the engine oil. (See «ENGINE OIL REPLACEMENT [MZI 3.7 V6]»(ref-581678-S34035266962013101400000).)
2. Remove the engine and transaxle component. (See «ENGINE REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581682-S09006967352013101400000).)
3. Secure the engine and transaxle component using a hoist and the SST. WARNING: Protect and stabilize the lowered engine and transaxle component with crossties to prevent injury or damage due to roll over. (Scheme 41): Securing Engine And Transaxle Using Hoist And SST
4. Remove the dynamic chamber and throttle body as a single unit. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581679-S24618371532013101400000).)
5. Remove the ignition coils. (See «IGNITION COIL REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581671-S40527084762013101400000).)
6. Remove the dipstick.
7. Remove the power steering oil pump drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581682-S41506096782013101400000).)
8. Remove the power steering oil pump. (See «POWER STEERING OIL PUMP REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581622-S32034916752013101400000).)
9. Remove the timing chain component. (See «TIMING CHAIN REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581682-S41092184032013101400000).)
10. Remove in the order indicated in the table.
11. Install in the reverse order of removal.
12. Start the engine and: Inspect the runout and contact on the pulley and belt. Inspect for engine oil, engine coolant, ATF, power steering fluid and fuel leakage. Verify the ignition timing, idle speed and idle mixture. (See «ENGINE TUNE-UP [MZI 3.7 V6]»(ref-581682-S20007164582013101400000).) Engine accessories operation.
13. Perform a road test. (Scheme 42): Water Pump Components With Torque Specifications

Scheme 41

Scheme 42

1. Loosen the upper timing chain guide (RH) bolt A. (Scheme 43): Identifying Upper Timing Chain Guide (RH) Bolt A And Bolt B
2. Remove the upper timing chain guide (RH) bolt B.
3. Move the upper timing chain guide (RH) as shown. (Scheme 44): Identifying Upper Timing Chain Guide (RH) And Bolt A
4. Retighten the bolt A.

Water Pump Removal Note

Note. When the water pump is removed, the engine coolant may flow through the cylinder block and penetrate the oil pan. To prevent the engine coolant from accumulating in the oil pan, remove the oil pan drain plug before removing the water pump.

Scheme 43

1. Remove the oil pan drain plug. (See «ENGINE OIL REPLACEMENT [MZI 3.7 V6]»(ref-581678-S34035266962013101400000).)
2. To prevent engine coolant from penetrating the oil pan, line the cylinder block with plastic sheeting as shown in the figure before removing the water pump. (Scheme 45): Covering Oil Pan And Cylinder Block With Plastic Sheeting

Scheme 44

1. Tighten the water pump bolts in the order shown in the figure. (Scheme 46): Identifying Water Pump Bolt Tightening Sequence Tightening torque 9-11 N.m {92-112 kgf.cm, 80-97 in.lbf}

COOLING FAN MOTOR REMOVAL/INSTALLATION [MZI 3.7 V6]

Scheme 45

1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZI 3.7 V6]»(ref-581683-S26168476562013101400000).)
3. Remove the air cleaner and fresh air duct component. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581679-S24618371532013101400000).)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZI 3.7 V6]»(ref-581683-S26168476562013101400000).)
7. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZI 3.7 V6]»(ref-581683-S19761424272013101400000).) (Scheme 47): Cooling Fan Motor Components With Torque Specifications

ATF Oil Cooler Pipe Removal Note

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.

Scheme 46

1. Remove the cooling fan component from above the engine compartment. (Scheme 48): Removing Cooling Fan Component From Engine Compartment

Scheme 47

1. Verify that the battery is fully charged. (See «BATTERY INSPECTION [MZI 3.7 V6]»(ref-581639-S39617389352013101400000).)
2. Disconnect the cooling fan motor connector (2 terminals).
3. Install a tester and battery to the cooling fan motor connector (2 terminals) as shown in the figure. see scheme 28: Tester, Battery And Cooling Fan Motor Connector (2 Terminals)
4. Verify that each cooling fan motors operate smoothly at the standard current. If there is any malfunction, replace the applicable part. Cooling fan motor No.1, No.2 standard current 22.5-25.5 A [12 V]

Scheme 48

1. Connect the M-MDS to the DLC-2.
2. Start and warm up the engine.
3. Monitor the engine coolant temperature with the M-MDS.
4. Measure the voltage at terminal A of the fan control module connector (2 terminals) as shown in the table. see scheme 29: Measuring Voltage At Terminal A Of Fan Control Module Connector (2 Terminals) If not within the specification, inspect the input signals from the following parts. Cylinder Head Temperature (CHT) sensor Refrigerant pressure switch (middle) FAN CONTROL MODULE [A/C OFF (AMBIENT TEMP. -5-43 °C {23-109 °F})] Inspection Result Engine coolant temp. (°C {°F}) PID FAN_DUTY Voltage 100 {212} 0 % 0 V 100-104 {212-219} 0-70 % 0-9.6 V 106 {223} 100 % 13.0 V FAN CONTROL MODULE [A/C ON (AMBIENT TEMP. -1-43 °C {31-109 °F})] Inspection Result Refrigerant pressure (MPa{kgf/cm 2, psi}) PID FAN_DUTY Voltage less than 1.20 {12.2, 174} 43 % 5.9 V more than 1.96 {20.0, 284} 100 % 13.0 V
5. If all the above parts are normal, replace the fan control module.