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Cooling System: Removal & Installation Mazda MX-5 NC

Cooling System (Mechanical) 8 illustrations ~952 words

ENGINE COOLANT REPLACEMENT [LF]

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)

7.5 L {7.9 US qt, 6.6 Imp qt}

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7
  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. Tightening torque 0.8-1.5 N.m {8-15 kgf.cm, 7-13 in.lbf}
  6. Referring to «ANTIFREEZE SOLUTION MIXTURE PERCENTAGE TABLE»(ref-244456-S21325503362006092400000) , select the correct volume percentage of the water and 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 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 water 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 coolant temperature to prevent overheating. Run the engine at approx. 2,500 rpm for 5 min . Run the engine at approx. 3,000 rpm for 5s , then idle. Repeat step 2 4-5 times.
  11. Stop the engine, and inspect the coolant level after the coolant temperature decreases. If it is low, repeat steps 7 thru 10 .
  12. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [LF]»(ref-244456-S03120278262006092400000) .)

COOLANT RESERVE TANK REMOVAL/INSTALLATION [LF]

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 8

Scheme 8
Scheme 8
  1. Drain the engine coolant until the coolant reserve tank becomes empty. (See «ENGINE COOLANT REPLACEMENT [LF]»(ref-244456-S02885124352006092400000).)
  2. Remove in the order indicated in (Scheme 9).
  3. Install in the reverse order of removal.
  4. Add engine coolant. (See «ENGINE COOLANT REPLACEMENT [LF]»(ref-244456-S02885124352006092400000).)
  5. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [LF]»(ref-244456-S03120278262006092400000).)

RADIATOR REMOVAL/INSTALLATION [LF]

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. Remove the splash shield and under cover.
  2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [LF]»(ref-244456-S02885124352006092400000) .)
  3. Remove the battery, battery tray, and battery duct. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-244448-S25513985422006092400000) .)
  4. Remove the air cleaner. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-244455-S24513161252006092400000) .)
  5. Remove the PCM and air cleaner insulator. (See «PCM REMOVAL/INSTALLATION [LF]»(ref-244452-S11022070362006092400000) .)
  6. Remove the coolant reserve tank. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [LF]»(ref-244456-S09894892712006092400000) .)
  7. Disconnect the ATF oil cooler hose. (AT)
  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 [LF]»(ref-244456-S02885124352006092400000) .)
  11. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [LF]»(ref-244456-S03120278262006092400000) .)
  12. Inspect the ATF level. (AT) (See «AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [SJ6A-EL]»(ref-244474-S26474444892006092400000) .)

Scheme 9

Scheme 9
Scheme 9

P/S Cooling Pipe Removal Note

  1. Remove the P/S cooling pipe with the hoses still connected.

Condenser Removal Note

  1. Remove the condenser with the cooler pipes still connected.

THERMOSTAT REMOVAL/INSTALLATION [LF]

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 10

Scheme 10
Scheme 10
  1. Remove the battery cover.
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-244448-S25513985422006092400000).)
  3. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [LF]»(ref-244456-S02885124352006092400000).)
  4. Remove the throttle body. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-244455-S24513161252006092400000).)
  5. Remove in the order indicated in (Scheme 11).
  6. Install in the reverse order of removal.
  7. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [LF]»(ref-244456-S02885124352006092400000).)
  8. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [LF]»(ref-244456-S03120278262006092400000).)

WATER PUMP REMOVAL/INSTALLATION [LF]

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 11

Scheme 11
Scheme 11
  1. Remove the battery cover.
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-244448-S25513985422006092400000).)
  3. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [LF]»(ref-244456-S02885124352006092400000).)
  4. Remove the air cleaner. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-244455-S24513161252006092400000).)
  5. Loosen the water pump pulley bolt and remove the drive belt. (See «DRIVE BELT REPLACEMENT [LF]»(ref-244453-S32071317942006092400000).)
  6. Remove in the order indicated in (Scheme 12).
  7. Install in the reverse order of removal.
  8. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [LF]»(ref-244456-S02885124352006092400000).)
  9. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [LF]»(ref-244456-S03120278262006092400000).)

FAN MOTOR REMOVAL/INSTALLATION [LF]

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 12

Scheme 12
Scheme 12
  1. Remove the splash shield and under cover.
  2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [LF]»(ref-244456-S02885124352006092400000) .)
  3. Remove the battery, battery tray, and battery duct. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-244448-S25513985422006092400000) .)
  4. Remove the air cleaner. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-244455-S24513161252006092400000) .)
  5. Remove the PCM and air cleaner insulator. (See «PCM REMOVAL/INSTALLATION [LF]»(ref-244452-S11022070362006092400000) .)
  6. Remove the coolant reserve tank. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [LF]»(ref-244456-S09894892712006092400000) .)
  7. Disconnect the ATF oil cooler hose. (AT)
  8. Remove the radiator and cooling fan component. (See «RADIATOR REMOVAL/INSTALLATION [LF]»(ref-244456-S02966534782006092400000) .)
  9. Remove in the order indicated in the table.
  10. Install in the reverse order of removal.
  11. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [LF]»(ref-244456-S02885124352006092400000) .)
  12. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [LF]»(ref-244456-S03120278262006092400000) .)
  13. Inspect the ATF level. (AT) (See «AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [SJ6A-EL]»(ref-244474-S26474444892006092400000) .)

Scheme 13

Scheme 13: Part Inspection
Scheme 13: Part Inspection
  1. Verify that the battery is fully charged.
  2. Install a tester and battery to the cooling fan motor connector (4 terminals) see scheme 15 FAN MOTOR OPERATION TABLE Fan motor rotation speed Connection terminal Positive Negative High A and C B and D Middle C B and D Low C B
  3. Verify that fan motor operates smoothly at the standard current. If there is any malfunction, replace the applicable part. Cooling fan motor current High: 9.0-12.0 A Middle: 6.4-9.4 A Low: 4.8-7.8 A

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