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Cooling System: Removal & Installation Mazda CX-7 I

Cooling System (Mechanical) 12 illustrations ~1380 words

ENGINE COOLANT REPLACEMENT[L3 WITH TC]

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 FL22 type engine coolant. FL22 type engine coolant is shipped as a diluted solution (55% coolant, 45% water). Use the solution as is when replacing coolant.

Engine coolant capacity (approx. quantity) 9.0 L {9.5 US qt, 7.9 lmp qt}

Scheme 34

Scheme 34
Scheme 34

Scheme 35

Scheme 35
Scheme 35
  1. Remove the cooling system cap.
  2. Remove 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 with a new gasket. Tightening torque 1.5-2.4 N.m {15-25 kgf.cm, 13-21 in.lbf}
  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 CHART 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 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 FULL 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 approx. 5,000 rpm for 1 min. Run the engine at idle for 5 s. Repeat steps ( 1 ), ( 2 ) several times. Operate the heater at the maximum temperature and airflow, and verify that hot air blows from vent.
  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[L3 WITH TC]»(ref-268964-S21741168822007102700000) .)

RADIATOR REMOVAL/INSTALLATION[L3 WITH TC]

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 ft.
  1. Disconnect the negative battery cable.
  2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT[L3 WITH TC]»(ref-268964-S25805555392007102700000) .)
  3. Remove the charge air cooler duct, air cleaner and fresh air duct component. (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268965-S28635226732007102700000) ).
  4. Remove the coolant reserve tank. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268964-S10390752252007102700000) .)
  5. Remove the dipstick pipe. (See «OIL PAN REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268963-S23117871082007102700000) ).
  6. Remove the cooling fan component. (See «FAN MOTOR REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268964-S32785521252007102700000) .)
  7. Remove the under cover.
  8. Disconnect the ATF oil cooler hose from the radiator.
  9. Remove in the order indicated in the table.
  10. Install in the reverse order of the removal.
  11. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT[L3 WITH TC]»(ref-268964-S25805555392007102700000) ).
  12. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION[L3 WITH TC]»(ref-268964-S21741168822007102700000) .)
  13. Inspect the ATF level. (See «AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION[AW6A-EL, AW6AX-EL]»(ref-269007-S20607917802007102700000) ).

Scheme 36

Scheme 36
Scheme 36

Upper Mount Rubber Bracket Removal Note

CAUTIONDo not apply force excessively and in the directions that are not specified, otherwise the upper mount rubber bracket could be damaged.

Scheme 37

Scheme 37: RH
Scheme 37: RH
  1. Remove the upper mount rubber bracket while pressing down the upper mount rubber bracket tab in the direction of the arrow.

Scheme 38

Scheme 38: LH
Scheme 38: LH

Scheme 39

Scheme 39
Scheme 39
  1. Insert a flathead screwdriver into the upper mount rubber bracket notch.
  2. Apply force in the direction shown by the arrow.

Radiator Removal Note

  1. Remove the radiator from above the engine compartment.

THERMOSTAT REMOVAL/INSTALLATION[L3 WITH TC]

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.

Scheme 40

Scheme 40
Scheme 40
  1. Disconnect the negative battery cable.
  2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT[L3 WITH TC]»(ref-268964-S25805555392007102700000) .)
  3. Remove the front splash shield (RH).
  4. Remove the charge air cooler duct. (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268965-S28635226732007102700000) ).
  5. Remove the drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268962-S17874516452007102700000) ).
  6. 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»(ref-269012-S19109706422007102700000) ).
  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[L3 WITH TC]»(ref-268964-S25805555392007102700000) .)
  10. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION[L3 WITH TC]»(ref-268964-S21741168822007102700000) .).

WATER PUMP REMOVAL/INSTALLATION[L3 WITH TC]

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.

Scheme 41

Scheme 41
Scheme 41
  1. Disconnect the negative battery cable.
  2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT[L3 WITH TC]»(ref-268964-S25805555392007102700000) .)
  3. Remove the front splash shield (RH).
  4. Remove the charge air cooler duct. (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268965-S28635226732007102700000) ).
  5. Loosen the water pump pulley bolts before removing the drive belt.
  6. Remove the drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268962-S17874516452007102700000) ).
  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[L3 WITH TC]»(ref-268964-S25805555392007102700000) .)
  10. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION[L3 WITH TC]»(ref-268964-S21741168822007102700000) .).

O-ring Installation Note

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

FAN MOTOR REMOVAL/INSTALLATION[L3 WITH TC]

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.

Scheme 42

Scheme 42
Scheme 42
  1. Disconnect the negative battery cable.
  2. Remove the under cover.
  3. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT[L3 WITH TC]»(ref-268964-S25805555392007102700000) .)
  4. Remove the charge air cooler duct, air cleaner and fresh air duct component. (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268965-S28635226732007102700000) ).
  5. Remove the coolant reserve tank. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268964-S10390752252007102700000) .)
  6. Remove the dipstick pipe. (See «OIL PAN REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268963-S23117871082007102700000) ).
  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[L3 WITH TC]»(ref-268964-S25805555392007102700000) .)
  10. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION[L3 WITH TC]»(ref-268964-S21741168822007102700000) .)

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.

Cooling Fan Component Removal Note

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

Scheme 43

Scheme 43: Part Inspection
Scheme 43: Part Inspection
  1. Verify that the battery is fully charged. (See «BATTERY INSPECTION[L3 WITH TC]»(ref-268969-S30305553962007102700000) ).
  2. Remove the charge air cooler duct. (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268965-S28635226732007102700000) ).
  3. Disconnect the cooling fan motor connector (2 terminals).
  4. Install a tester and battery to the cooling fan motor connector (2 terminals) as shown in the figure.
  5. Verify that each 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 17.5-22.5 A

Scheme 44

Scheme 44: FAN CONTROL MODULE INSPECTION[L3 WITH TC]
Scheme 44: FAN CONTROL MODULE INSPECTION[L3 WITH TC]

Scheme 45

Scheme 45
Scheme 45
  1. Remove the charge air cooler duct. (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC]»(ref-268965-S28635226732007102700000) ).
  2. Connect the M-MDS to the DLC-2.
  3. Start and warm up the engine.
  4. Monitor the engine coolant temperature with the M-MDS.
  5. Measure the voltage at terminal A of the fan control module connector (2 terminals) as shown in the table. If not within the specification, inspect the input signals from the following parts. Crankshaft Position (CKP) sensor Engine Coolant Temperature (ECT) sensor Throttle Position (TP) sensor Refrigerant pressure switch (middle) Fan control module NO. 1 FAN CONTROL MODULE NO. 1 VOLTAGE REFERENCE CHART Inspection Result Condition A/C Engine coolant temp. IG SW ON OFF 95°C {203°F} or less 0 V (Fan stops.) IG SW ON (Idling) OFF 95°C {203°F} or less 0 V (Fan stops.) IG SW ON (Idling) ON (1) 95°C {203°F) or less 4.1 V IG SW ON (Idling) ON (2) 95°C {203°F} or less 6.2 V IG SW ON (Idling) OFF 100°C {212°F} or more 4.1-14.6 V (1) Refrigerant pressure switch (middle) is off. (2) Refrigerant pressure switch (middle) is on. Fan control module NO. 2 FAN CONTROL MODULE NO. 2 VOLTAGE REFERENCE CHART Inspection Result Condition A/C Engine coolant temp. IG SW ON OFF 95°C {203°F} or less 0 V (Fan stops.) IG SW ON (Idling) OFF 95°C {203°F} or less 0 V (Fan stops.) IG SW ON (Idling) ON (1) 95°C {203°F} or less 5.5 V IG SW ON (Idling) ON (2) 95°C {203°F} or less 10.3 V IG SW ON (Idling) OFF 100°C {212°F} or more 4.1-14.6 V (1) Refrigerant pressure switch (middle) is off. (2) Refrigerant pressure switch (middle) is on.
  6. If all the above parts are normal, replace the fan control module.

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