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Cooling System: Removal & Installation Mazda RX-8 I

Cooling System (Mechanical) 16 illustrations ~798 words

ENGINE COOLANT REPLACEMENT

WARNINGRemove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury. 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 that can be damaged by alcohol or methanol antifreeze. Do not use alcohol or methanol in the cooling system. Use only ethylene-glycol-based coolant. Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will reduce the coolant's effectiveness. Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12
  1. Remove the cooling system cap.
  2. Loosen the radiator drain plug and drain the engine coolant.
  3. After completely draining the engine coolant, tighten the radiator drain plug.
  4. Add engine coolant into the coolant reserve tank up to the F mark.
  5. Install the cooling system cap.
  6. Start the engine and warm it up by idling. CAUTION: If the water temperature gauge rises too high, stop the engine and decrease the water temperature to prevent overheating.
  7. After the engine warms up, perform the following steps. Run the engine at approx. 2,500 RPM for 5 min. Run the engine at approx. 3,000 RPM for 5 min , then return to idling. Repeat this procedure several times.
  8. Stop the engine, wait until it is cool, and check the engine coolant level. If the engine coolant decreases, repeat Steps 4 - 8 .
  9. Inspect each area for engine coolant leakage.

COOLANT RESERVE TANK REMOVAL/INSTALLATION

WARNINGRemove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14
  1. Remove the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000).)
  2. Remove the battery cover.
  3. Disconnect the negative battery cable.
  4. Remove the battery, battery box.
  5. Remove the air cleaner component, air cleaner insulator. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION»(ref-178322-S25288823672005061400000).)
  6. Drain the engine coolant until the coolant reserve tank becomes empty. (See «ENGINE COOLANT REPLACEMENT»(ref-178321-S36202521982005061400000).)
  7. Remove in the order indicated. (Scheme 13)
  8. Install in the reverse order of removal.
  9. Add the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-178321-S36202521982005061400000).)
  10. Inspect for the engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION»(ref-178321-S21374804942005061400000).)

RADIATOR REMOVAL/INSTALLATION

WARNINGRemove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

Scheme 15

Scheme 15
Scheme 15
  1. Remove the engine cover. See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000).
  2. Remove the battery cover.
  3. Disconnect the negative battery cable.
  4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-178321-S36202521982005061400000).)
  5. Remove the following. Splash shield Under cover Battery, battery box Air cleaner component, air cleaner insulator (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION»(ref-178322-S25288823672005061400000).) PCM duct
  6. Position the coolant reserve tank out of the way. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION»(ref-178321-S38186091832005061400000).)
  7. Disconnect the ATF oil cooler hose. (A/T)
  8. Remove in the order indicated. (Scheme 15)
  9. Install in the reverse order or removal.
  10. Add engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-178321-S36202521982005061400000).)
  11. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION»(ref-178321-S21374804942005061400000).)

THERMOSTAT REMOVAL/INSTALLATION

WARNINGRemove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17
  1. Remove the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000).)
  2. Remove the battery cover.
  3. Disconnect the negative battery cable.
  4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-178321-S36202521982005061400000).)
  5. Remove the battery, battery box.
  6. Remove the secondary air control valve. (See SECONDARY AIR INJECTION (AIR) CONTROL VALVE REMOVAL/INSTALLATION.)
  7. Before positioning the drive belt out of the way, loosen the water pump pulley installation bolt.
  8. Position the drive belt out of the way. (See DRIVE BELT REPLACEMENT.)
  9. Remove the water pump pulley. (See «WATER PUMP REMOVAL/INSTALLATION»(ref-178321-S08139994362005061400000).)
  10. Remove in the order indicated. (Scheme 16)
  11. Install in the reverse order of removal.
  12. Add engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-178321-S36202521982005061400000).)
  13. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION»(ref-178321-S21374804942005061400000).)

Scheme 18

Scheme 18: Thermostat Installation Note
Scheme 18: Thermostat Installation Note
  1. Install the thermostat by fitting the projection on the thermostat to the recess of the thermostat case.
  2. Install the thermostat.

Scheme 19

Scheme 19: THERMOSTAT INSPECTION
Scheme 19: THERMOSTAT INSPECTION
  1. Inspect the thermostat for the following. WARNING: During inspection, the thermostat and water are extremely hot and they can cause burns. Do not touch the thermostat and water. The valve shall not open under normal temperature. Opening temperature and valve lift If there is any malfunction, replace the thermostat.

WATER PUMP REMOVAL/INSTALLATION

WARNINGRemove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21
  1. Remove the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000).)
  2. Remove the battery cover.
  3. Disconnect the negative battery cable.
  4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-178321-S36202521982005061400000).)
  5. Remove the battery, battery box, battery tray.
  6. Before positioning the drive belt out of the way, loosen the water pump pulley installation bolt.
  7. Position the drive belt out of the way.
  8. Remove in the order indicated. (Scheme 20)
  9. Install in the reverse order of removal.
  10. Add engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-178321-S36202521982005061400000).)
  11. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION»(ref-178321-S21374804942005061400000).)

Scheme 22

Scheme 22: FAN MOTOR REMOVAL/INSTALLATION
Scheme 22: FAN MOTOR REMOVAL/INSTALLATION

Scheme 23

Scheme 23
Scheme 23
  1. Remove the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000).)
  2. Remove the battery cover.
  3. Disconnect the negative battery cable.
  4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-178321-S36202521982005061400000).)
  5. Remove the following. Splash shield Under cover Battery, battery box. Air cleaner component, air cleaner insulator (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION»(ref-178322-S25288823672005061400000).) PCM duct
  6. Position the coolant reserve tank out of the way. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION»(ref-178321-S38186091832005061400000).)
  7. Disconnect the ATF oil cooler hose. (A/T)
  8. Remove the radiator and cooling fan component. (See «RADIATOR REMOVAL/INSTALLATION»(ref-178321-S03285103822005061400000).)
  9. Remove in the order indicated. (Scheme 22)
  10. Install in the reverse order of removal.
  11. Add engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-178321-S36202521982005061400000).)
  12. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION»(ref-178321-S21374804942005061400000).)

Scheme 24

Scheme 24: Part Inspection
Scheme 24: Part Inspection

Scheme 25

Scheme 25
Scheme 25
  1. Verify that the battery voltage is 12 V .
  2. Install a tester and battery to the cooling fan motor connector as shown in the figure.
  3. Verify that each fan motor operates smoothly at the standard current. If there is any malfunction, replace the applicable part.

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