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2007 ENGINE Cooling System (L3) - Mazda5

COOLING SYSTEM LOCATION INDEX [L3]


Fig. 1: Identifying Cooling System Component Location Courtesy of MAZDA MOTORS CORP.

COOLING SYSTEM SERVICE WARNINGS [L3]


WARNING:

Never 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.

ENGINE COOLANT LEVEL INSPECTION [L3]


WARNING:

Never 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. 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.

NOTE:

1. Remove the cooling system cap and verify that the engine coolant is filled close to the top of the cooling system filler neck. 2. Verify that the engine coolant level in the coolant reserve tank is between the L and F marks. 3. If the engine coolant level is below L mark, add engine coolant. Fig. 2: Identifying Proper Cooling System Cap Courtesy of MAZDA MOTORS CORP.

ENGINE COOLANT PROTECTION INSPECTION [L3]


1. Measure the 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. 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.

NOTE:

Fig. 3: Identifying Proper Cooling System Cap Courtesy of MAZDA MOTORS CORP. 3. Determine the coolant protection level by referring to the graph shown. If the coolant protection level is not correct, add water or coolant. Fig. 4: Coolant Temperature Graph Courtesy of MAZDA MOTORS CORP.

ENGINE COOLANT REPLACEMENT [L3]


WARNING:

Never 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. 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. 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.

CAUTION:

NOTE:

Engine coolant capacity (approx. quantity) 7.0 L {7.4 US qt, 6.2 Imp qt} 1. Remove the coolant reserve tank with the hose still connected. 2. Remove the coolant reserve tank cap and drain the engine coolant from the coolant reserve tank.

Fig. 5: Identifying Proper Cooling System Cap Courtesy of MAZDA MOTORS CORP. 3. Remove the cooling system cap. 4. Remove the battery duct. (See BATTERY REMOVAL/INSTALLATION [L3] ). Fig. 6: Removing Cooling System Cap Courtesy of MAZDA MOTORS CORP. 5. Loosen the radiator drain plug and drain the engine coolant into a container. 6. Flush the cooling system with water until all traces of color are gone. 7. Let the system drain completely. 8. Tighten the radiator drain plug. Fig. 7: Locating Radiator Drain Plug Courtesy of MAZDA MOTORS CORP. 9. Referring to the following chart, select the correct volume percentage of the water and coolant. Antifreeze solution mixture percentage (Except FL22 type engine coolant) ENGINE COOLANT SPECIFICATION Engine coolant protection Above-16 C {3 F} Above-26 C {-15 F} Above -40 C {-40 F} Volume percentage (%) Gravity at 20 C {68 F} Water Coolant 65 35 1.057 55 45 1.072 45 55 1.086

10. Refill the coolant from the cooling system filler neck until it is close to the top of the cooling system filler neck. 11. Refill the coolant into the coolant reserve tank up to the F mark on the tank. 12. 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.

13. Start the engine and warm up the engine by idling. 14. After the engine warms up, perform the following steps. At this time, be careful of the coolant temperature to prevent overheating. 1. Run the engine at approx. 2,500 RPM for 5 min.

2. Run the engine at approx. 3,000 RPM for 5 s, then idle. 3. Repeat step (2) 4-5 times. 15. Stop the engine, and inspect the coolant level after the coolant temperature decreases. If it is low, repeat steps 10-14. 16. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [L3]).

ENGINE COOLANT LEAKAGE INSPECTION [L3]


WARNING:

Never 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. Inspect the engine coolant level. (See ENGINE COOLANT LEVEL INSPECTION [L3]). 2. Remove the cooling system cap. 3. Clean the installation parts of the cooling system cap and the upper radiator hose. 4. Install the SST and a radiator cap tester to the cooling system filler neck. 5. Apply pressure using the radiator cap tester. CAUTION:

Applying more than 122.6 kPa {1.25 kgf/cm2 , 17.8 psi} can damage the hoses, fittings, and other components, and cause leakage.

Pressure 122.6 kPa {1.25 kgf/cm2 , 17.8 psi} [1 min] Fig. 8: Pressurizing Radiator Cap Using Tester Courtesy of MAZDA MOTORS CORP. 6. When pressurizing the cooling system, verify that the pressure is maintained. If the gauge needle drops, it may indicate water leakage, therefore perform leakage inspection.

If engine coolant leaks from the upper hose installation part, replace the upper hose and the clamp. o If the engine coolant leaks from the main body of the radiator (caulked part), replace the radiator.

COOLING SYSTEM CAP INSPECTION [L3]


WARNING:

Never 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're sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

1. Clean the cooling system cap and the sealed part. 2. Inspect for cracks or roll up on the sealed part of the cooling system cap. If there is any malfunction, replace the cooling system cap. 3. Attach the cooling system cap to the SST and a radiator cap tester. 4. Hold the cooling system cap downward and apply pressure gradually. Verify that the pressure is held stable for 10 s. If the pressure is not held stable, replace the cooling system cap. Cooling system cap valve opening pressure 93.2-122.6 kPa {0.95-1.25 kgf/cm2 , 13.5- 17.8 psi} Fig. 9: Pressurizing Radiator Cap Using Tester Courtesy of MAZDA MOTORS CORP.

COOLANT RESERVE TANK REMOVAL/INSTALLATION [L3]


WARNING:

Never 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're sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

1. Remove in the order indicated in the table. COOLANT RESERVE TANK CHART 1 Hose 2 Coolant reserve tank 2. Install in the reverse order of removal. Fig. 10: Coolant Reserve Tank Courtesy of MAZDA MOTORS CORP.

RADIATOR REMOVAL/INSTALLATION [L3]


WARNING:

Never 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're sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

1. Remove the battery cover and battery duct. (See BATTERY REMOVAL/INSTALLATION [L3] ). 2. Disconnect the negative battery cable. 3. Remove the under cover. 4. Remove the cooling fan component. (See FAN MOTOR REMOVAL/INSTALLATION [L3]). 5. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [L3]). 6. Remove the air cleaner. (See INTAKE AIR SYSTEM REMOVAL/INSTALLATION [L3] ). 7. Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION ). 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 [L3]). 11. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [L3]). RADIATOR COMPONENT CHART 1 Radiator lower hose 2 Radiator upper hose Upper mount rubber bracket 3 (See UPPER MOUNT RUBBER BRACKET REMOVAL NOTE). 4 Upper mount rubber 5 Cooling system filler neck Radiator 6 (See RADIATOR REMOVAL NOTE). (See RADIATOR INSTALLATION NOTE). Fig. 11: Radiator Components & Torque Specification Courtesy of MAZDA MOTORS CORP. UPPER MOUNT RUBBER BRACKET REMOVAL NOTE 1. Remove the upper mount rubber bracket while pressing down the upper mount rubber bracket tab in the direction of the arrow. Fig. 12: Removing Upper Mount Rubber Bracket Courtesy of MAZDA MOTORS CORP. RADIATOR REMOVAL NOTE 1. Tilt the radiator to the engine side. 2. While lifting the radiator, remove the lower mount rubber (LH) from the mount installation hole. 3. While lifting the radiator, remove the lower mount rubber (RH) from the mount installation hole. Fig. 13: Removing Radiator Lower Mount Rubber Courtesy of MAZDA MOTORS CORP. 4. Remove the condenser from the radiator with the pipes still connected, by pressing the radiator side tab to unlock the tab C on the condenser. 5. Remove the radiator from below. Fig. 14: Identifying Radiator Side Tab Courtesy of MAZDA MOTORS CORP.

RADIATOR INSTALLATION NOTE 1. Install the condenser to the radiator by aligning lower side tab C with the radiator side tab, install upper tab C, then install lower side tab C. Fig. 15: Identifying Radiator Side Tab Courtesy of MAZDA MOTORS CORP.

THERMOSTAT REMOVAL/INSTALLATION [L3]


WARNING:

Never 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're sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [L3] ). 2. Disconnect the negative battery cable. 3. Remove the under cover and splash shield as a single unit. 4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [L3]). 5. Position the coolant reserve tank out of the way. 6. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [L3] ). 7. Position the drive belt out of the way. (See DRIVE BELT REPLACEMENT [L3] ). 8. Remove the drive belt tensioner. (See TIMING CHAIN REMOVAL/INSTALLATION [L3] ). 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 [L3]). 12. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [L3]). THERMOSTAT COMPONENT CHART 1 Bypass hose 2 Lower radiator hose

3 Thermostat component 4 Gasket Fig. 16: Thermostat & Torque Specification Courtesy of MAZDA MOTORS CORP.

THERMOSTAT INSPECTION [L3]


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 should not open under normal temperature. Opening temperature and valve lift o If there is malfunction, replace the thermostat. Thermostat initial-opening temperature 80-84 C {176-183 F} Thermostat full-open temperature 97 C {207 F} Thermostat full-open lift More than 8.0 mm {0.31 in}

WATER PUMP REMOVAL/INSTALLATION [L3]


WARNING:

Never 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're sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [L3] ).

2. Disconnect the negative battery cable. 3. Remove the under cover and splash shield as a single unit. 4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [L3]). 5. Position the coolant reserve tank out of the way. 6. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [L3] ). 7. Loosen the water pump pulley bolt and position the drive belt out of the way. (See DRIVE BELT REPLACEMENT [L3] ). 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 [L3]). 11. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [L3]). WATER PUMP COMPONENT CHART 1 Water pump pulley 2 Water pump 3 O-ring Fig. 17: Water Pump & Torque Specification Courtesy of MAZDA MOTORS CORP.

FAN MOTOR REMOVAL/INSTALLATION [L3]


WARNING:

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

1. Remove the battery cover and battery duct. (See BATTERY REMOVAL/INSTALLATION [L3] ). 2. Disconnect the negative battery cable. 3. Remove the under cover. 4. Remove in the order indicated in the table. FAN MOTOR COMPONENT CHART 1 Fan control module connector Cooling fan component 2 (See COOLING FAN COMPONENT REMOVAL NOTE). (See COOLING FAN COMPONENT INSTALLATION NOTE). 3 Fan control module

4 Cooling fan 5 Cooling fan motor 6 Radiator cowling 5. Install in the reverse order of removal. Fig. 18: Cooling Fan Motor & Torque Specification Courtesy of MAZDA MOTORS CORP. COOLING FAN COMPONENT REMOVAL NOTE 1. Release the left and right tabs on the upper side of the radiator by pressing them in the direction shown in the figure. Fig. 19: Releasing Left And Right Tabs On Upper Side Of Radiator Courtesy of MAZDA MOTORS CORP. 2. Lift the cooling fan component to remove it from the left and right insertion areas on the lower side of the radiator. 3. Remove the cooling fan component from below. Fig. 20: Identifying Left And Right Insertion Areas Radiator Courtesy of MAZDA MOTORS CORP. COOLING FAN COMPONENT INSTALLATION NOTE 1. Insert the cooling fan component in the left and right insertion areas on the lower side of the radiator, and then attach the left and right tabs on the upper side of the radiator.

FAN MOTOR INSPECTION [L3]


PART INSPECTION 1. Verify that the battery is fully charged. 2. Install a tester and battery to the cooling fan motor connector (2 terminals) as shown in the figure. 3. Verify that fan motor operates smoothly at the standard current. If there is any malfunction, replace the applicable part. Cooling fan motor current 17-23 A Fig. 21: Identifying Cooling Fan Motor Connector Courtesy of MAZDA MOTORS CORP.

FAN CONTROL MODULE INSPECTION [L3]


1. Start and warm up the engine. 2. Monitor the engine coolant temperature with the M-MDS or the equivalent. 3. Measure the voltage at terminal A of the fan control module connector (2 terminals) from the harness side as shown in the table. Fig. 22: Identifying Fan Control Module Connector Courtesy of MAZDA MOTORS CORP. ENGINE COOLANT TEMPERATURE SPECIFICATION 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 8.9-10.3 V IG SW ON (Idling) OFF 100 C {212 F} or more 4.1-14.6 V
(1)

Refrigerant pressure switch (middle) is on.

If not within the specification, inspect the input signals from the following parts. o Crankshaft Position (CKP) sensor o Engine Coolant Temperature (ECT) sensor o Throttle Position (TP) sensor o Refrigerant pressure switch (middle) 4. If all the above parts are normal, replace the fan control module.