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

ENGINE COOLANT REPLACEMENT [MZR 2.5]

Note. If the "FL22" mark is shown on or near the cooling system cap, use Mazda Genuine FL22 engine coolant. (Scheme 8): Identifying FL22 Mark On Cooling System Cap FL22 type engine coolant is shipped as a diluted solution. Use the solution as is when replacing coolant.

Engine coolant capacity (approx. quantity) [U.S.A. and CANADA]

1. MTX : 7.7 L {8.1 US qt, 6.8 Imp qt}
2. ATX : 7.6 L {8.0 US qt, 6.7 Imp qt}

Engine coolant capacity (approx. quantity) [Except U.S.A. and CANADA]

1. MTX : 7.9 L {8.3 US qt, 7.0 Imp qt}
2. ATX : 8.1 L {8.6 US qt, 7.1 Imp qt}

Scheme 7

1. Remove the cooling system cap.
2. Loosen the radiator drain plug and drain the engine coolant into a container. (Scheme 9): 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 {3.2 °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-581646-S26582918502013101400000).)

Scheme 8

Scheme 9

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 6: Identifying FL22 Mark On Cooling System Cap 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 7: Engine Coolant Protection Level Graph If the engine coolant protection level is not correct, add water or engine coolant.

RADIATOR REMOVAL/INSTALLATION [MZR 2.5]

Scheme 10

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 [MZR 2.5]»(ref-581646-S28004987162013101400000).)
4. Remove the air cleaner, air hose and fresh air duct component. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-581645-S06665670962013101400000).)
5. Remove the coolant reserve tank. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 2.5]»(ref-581646-S37465899902013101400000).)
6. Remove the cooling fan component. (See «COOLING FAN MOTOR REMOVAL/INSTALLATION [MZR 2.5]»(ref-581646-S06325450512013101400000).)
7. Disconnect the ATF oil cooler hose from the radiator. (ATX) (See «OIL COOLER REMOVAL/INSTALLATION [FS5A-EL]»(ref-581660-S27745390032013101400000).)
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-581646-S28004987162013101400000).)
11. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 2.5]»(ref-581646-S26582918502013101400000).)
12. Inspect the ATF level. (ATX) (See «AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION [FS5A-EL]»(ref-581660-S08068979012013101400000).) (Scheme 12): Identifying Radiator Removal Order

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 11

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 13): 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 12

1. Remove the four bolts which secure the condenser to the radiator and set the condenser apart from the radiator. (Scheme 14): Condenser To Radiator Bolts With Torque Specifications
2. Remove the radiator from above the engine compartment.

Scheme 13

Scheme 14

Scheme 15

1. Align the bracket groove of the condenser to the radiator positioning rib. (Scheme 15): Aligning Bracket Groove Of Condenser To Radiator Positioning Rib
2. Align the bracket notch of the condenser to the radiator positioning rib. (Scheme 16): Aligning Bracket Notch Of Condenser To Radiator Positioning Rib
3. Install the condenser installation bolts as shown in the figure. (Scheme 17): Condenser Bolts With Torque Specifications

THERMOSTAT REMOVAL/INSTALLATION [MZR 2.5]

Scheme 16

1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.5]»(ref-581646-S28004987162013101400000).)
3. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.5]»(ref-581643-S18902301812013101400000).)
4. Remove the drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION [MZR 2.5]»(ref-581643-S27542280922013101400000).)
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-581622-S26902976412013101400000).)
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-581646-S28004987162013101400000).)
9. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 2.5]»(ref-581646-S26582918502013101400000).) (Scheme 18): Thermostat Components With Torque Specifications

WATER PUMP REMOVAL/INSTALLATION [MZR 2.5]

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.

Scheme 17

1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.5]»(ref-581646-S28004987162013101400000).)
3. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.5]»(ref-581643-S18902301812013101400000).)
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-581643-S27542280922013101400000).)
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-581646-S28004987162013101400000).)
9. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 2.5]»(ref-581646-S26582918502013101400000).) (Scheme 19): Water Pump Components With Torque Specifications

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]

Scheme 18

1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [MZR 2.5]»(ref-581646-S28004987162013101400000).)
3. Remove the air cleaner, air hose and fresh air duct component. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]»(ref-581645-S06665670962013101400000).)
4. Remove the coolant reserve tank. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 2.5]»(ref-581646-S37465899902013101400000).)
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-581646-S28004987162013101400000).)
8. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [MZR 2.5]»(ref-581646-S26582918502013101400000).) (Scheme 20): Cooling Fan Motor Components With Torque Specifications

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.

Scheme 19

1. Remove the cooling fan component from above the engine compartment. (Scheme 21): Removing Cooling Fan Component From Engine Compartment

Scheme 20

1. Verify that the battery is fully charged. (See «BATTERY INSPECTION [MZR 2.5]»(ref-581638-S18800543152013101400000).)
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 22: 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 17.5-20.5 A [12 V]

Scheme 21

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 23: Identifying Fan Control Module Connector Terminals If not within the specification, inspect the input signals from the following parts. Engine Coolant Temperature (ECT) sensor FAN CONTROL MODULE [A/C OFF] Inspection Result Engine coolant temp. (°C {°F}) PID FAN_DUTY Voltage 100 {212} 30 % 6.5 V 100-110 {212-230} 30-100 % 6.5-13.0 V 110 {230} 100 % 13.0 V
5. If all the above parts are normal, replace the fan control module.