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Engine Cooling System: Removal & Installation Mazda RX-8 I рестайлинг

Cooling System (Mechanical) 10 illustrations ~1152 words

ENGINE COOLANT REPLACEMENT [13B-MSP]

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. Use the solution as is when replacing coolant.

Engine coolant capacity (approx. quantity)

MT: 10.0 L {10.6 US qt, 8.80 lmp qt}

AT: 9.8 L {10 US qt, 8.6 lmp qt}

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10
  1. Remove the cooling system cap.
  2. Loosen 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.
  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 (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 into the coolant reserve tank up to the F mark.
  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.
  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. Run the engine at approx. 2,500 RPM for 5 min . Run the engine at approx. 3,000 RPM for 5 s , then return to idling. Repeat step (2) several times.
  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 [13B-MSP]»(ref-367619-S36400923022010072700000) .)

COOLANT RESERVE TANK REMOVAL/INSTALLATION [13B-MSP]

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 engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION [13B-MSP]»(ref-367623-S37771794152010072700000) .)
  2. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .)
  3. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .)
  4. Remove the battery, battery box. (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .)
  5. Remove the air cleaner component, air cleaner insulator. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [13B-MSP]»(ref-367618-S14848159782010072700000) .)
  6. Drain the engine coolant until the coolant reserve tank becomes empty. (See «ENGINE COOLANT REPLACEMENT [13B-MSP]»(ref-367619-S09402478192010072700000) .)
  7. Remove in the order indicated in the figure.
  8. Install in the reverse order of removal.
  9. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [13B-MSP]»(ref-367619-S09402478192010072700000) .)
  10. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [13B-MSP]»(ref-367619-S36400923022010072700000) .)

RADIATOR REMOVAL/INSTALLATION [13B-MSP]

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 engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION [13B-MSP]»(ref-367623-S37771794152010072700000) .)
  2. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .)
  3. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .)
  4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [13B-MSP]»(ref-367619-S09402478192010072700000) .)
  5. Remove the following. Splash shield Aerodynamic under cover (See «AERODYNAMIC UNDER COVER REMOVAL/INSTALLATION»(ref-367654-S38607773612010072700000) .) Battery, battery box, battery tray, battery duct (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .) Air cleaner component, air cleaner insulator (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [13B-MSP]»(ref-367618-S14848159782010072700000) .)
  6. Position the coolant reserve tank out of the way. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [13B-MSP]»(ref-367619-S27677862052010072700000) .)
  7. Disconnect the ATF oil cooler hose from the radiator. (AT)
  8. Remove in the order indicated in the figure.
  9. Install in the reverse order of removal.
  10. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [13B-MSP]»(ref-367619-S09402478192010072700000) .)
  11. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [13B-MSP]»(ref-367619-S36400923022010072700000) .)
  12. Inspect the ATF level. (AT) (See «AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [SJ6A-EL]»(ref-367646-S17914281322010072700000) .)

Condenser Fitting Bolt Removal Note

  1. Remove the condenser fitting bolt, and position the condenser out of the way with the cooler pipes still connected.

THERMOSTAT REMOVAL/INSTALLATION [13B-MSP]

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 13

Scheme 13
Scheme 13
  1. Remove the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION [13B-MSP]»(ref-367623-S37771794152010072700000) .)
  2. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .)
  3. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .)
  4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [13B-MSP]»(ref-367619-S09402478192010072700000) .)
  5. Remove the battery, battery box. (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .)
  6. Remove the secondary air control valve. (See «SECONDARY AIR INJECTION (AIR) CONTROL VALVE REMOVAL/INSTALLATION [13B-MSP]»(ref-367621-S42892419672010072700000) .)
  7. Loosen the water pump pulley installation bolt.
  8. Position the drive belt out of the way. (See «DRIVE BELT REPLACEMENT [13B-MSP]»(ref-367623-S36063400392010072700000) .)
  9. Remove the water pump pulley. (See «WATER PUMP REMOVAL/INSTALLATION [13B-MSP]»(ref-367619-S16663388262010072700000) .)
  10. Remove in the order indicated in the figure.
  11. Install in the reverse order of removal.
  12. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [13B-MSP]»(ref-367619-S09402478192010072700000) .)
  13. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [13B-MSP]»(ref-367619-S36400923022010072700000) .)

Scheme 14

Scheme 14: Thermostat Installation Note
Scheme 14: Thermostat Installation Note
  1. Install the thermostat by fitting the projection on the thermostat to the recess of the thermostat case.

WATER PUMP REMOVAL/INSTALLATION [13B-MSP]

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 15

Scheme 15
Scheme 15
  1. Remove the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION [13B-MSP]»(ref-367623-S37771794152010072700000) .)
  2. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .)
  3. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .)
  4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [13B-MSP]»(ref-367619-S09402478192010072700000) .)
  5. Remove the battery, battery box, battery tray. (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .)
  6. Loosen the water pump pulley installation bolt.
  7. Position the drive belt out of the way. (See «DRIVE BELT REPLACEMENT [13B-MSP]»(ref-367623-S36063400392010072700000) .)
  8. Remove in the order indicated in the figure.
  9. Install in the reverse order of removal.
  10. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [13B-MSP]»(ref-367619-S09402478192010072700000) .)
  11. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [13B-MSP]»(ref-367619-S36400923022010072700000) .)

O-Ring Installation Note

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

COOLING FAN COMPONENT REMOVAL/INSTALLATION [13B-MSP]

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 16

Scheme 16
Scheme 16
  1. Remove the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION [13B-MSP]»(ref-367623-S37771794152010072700000) .)
  2. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .)
  3. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .)
  4. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [13B-MSP]»(ref-367619-S09402478192010072700000) .)
  5. Remove the following. Splash shield Aerodynamic under cover (See «AERODYNAMIC UNDER COVER REMOVAL/INSTALLATION»(ref-367654-S38607773612010072700000) .) Battery, battery box, battery tray, battery duct (See «BATTERY REMOVAL/INSTALLATION [13B-MSP]»(ref-367630-S30865077932010072700000) .) Air cleaner component, air cleaner insulator (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [13B-MSP]»(ref-367618-S14848159782010072700000) .)
  6. Position the coolant reserve tank out of the way. (See «COOLANT RESERVE TANK REMOVAL/INSTALLATION [13B-MSP]»(ref-367619-S27677862052010072700000) .)
  7. Disconnect the ATF oil cooler hose from the radiator. (AT)
  8. Remove the radiator and cooling fan component. (See «RADIATOR REMOVAL/INSTALLATION [13B-MSP]»(ref-367619-S24482503622010072700000) .)
  9. Remove in the order indicated in the figure.
  10. Install in the reverse order of removal.
  11. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [13B-MSP]»(ref-367619-S09402478192010072700000) .)
  12. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [13B-MSP]»(ref-367619-S36400923022010072700000) .)
  13. Inspect the ATF level. (AT) (See «AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [SJ6A-EL]»(ref-367646-S17914281322010072700000) .)

Scheme 17

Scheme 17: Part Inspection
Scheme 17: Part Inspection
  1. Verify that the battery is fully charged. (See «BATTERY INSPECTION [13B-MSP]»(ref-367630-S31771058522010072700000) .)
  2. Disconnect the cooling fan motor connector (4 terminals.)
  3. Install a tester and battery to the cooling fan motor connector (4 terminals) as shown in the figure.
  4. 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 7.7-10.7 A [12V]

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