Mazda 2: Cooling System

COOLING SYSTEM LOCATION INDEX

Mazda 2. COOLING SYSTEM LOCATION INDEX

  1. Cooling system cap
    • (See COOLING SYSTEM CAP INSPECTION)
  2. Cooling fan motor
    • (See COOLING FAN MOTOR REMOVAL/INSTALLATION)
    • (See COOLING FAN MOTOR INSPECTION)
  3. Coolant reserve tank
    • (See ENGINE COOLANT LEVEL INSPECTION)
    • (See COOLANT RESERVE TANK REMOVAL/INSTALLATION)
  4. Water pump
    • (See WATER PUMP REMOVAL/INSTALLATION)
  5. Thermostat
    • (See THERMOSTAT REMOVAL/INSTALLATION)
    • (See THERMOSTAT INSPECTION)
  6. Radiator
    • (See ENGINE COOLANT PROTECTION INSPECTION)
    • (See ENGINE COOLANT REPLACEMENT)
    • (See ENGINE COOLANT LEAKAGE INSPECTION)
    • (See RADIATOR REMOVAL/INSTALLATION)

COOLING SYSTEM SERVICE WARNINGS

WARNING:

ENGINE COOLANT LEVEL INSPECTION

WARNING:

NOTE:

Mazda 2. ENGINE COOLANT

1. Remove the cooling system cap.

2. Verify that the engine coolant is filled close to the top of the radiator filler neck.

3. Verify that the engine coolant level in the coolant reserve tank is between the FULL and LOW marks.

Mazda 2. ENGINE COOLANT

ENGINE COOLANT REPLACEMENT

WARNING:

CAUTION:

1. Use engine coolant at a concentration that meets the environmental conditions in which the vehicle is driven, otherwise engine damage could occur.

2. The engine has aluminum parts and must be protected by an ethylene-glycol-based coolant to prevent corrosion and freezing.

3. Do not use coolants containing Alcohol, Methanol, Borate or Silicate. These coolants could damage the cooling system.

4. Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut down on the coolant's effectiveness.

5. Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.

NOTE:

Mazda 2. ENGINE COOLANT

Engine coolant capacity (approx. quantity)

1. Remove the cooling system cap.

2. Loosen the radiator drain plug and drain the engine coolant into a container.

Mazda 2. ENGINE COOLANT

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)

Mazda 2. ENGINE COOLANT

7. Remove the battery to facilitate the removal/installation of the blind cap for air bleeding.

(See BATTERY REMOVAL/INSTALLATION).

8. Remove the blind cap installed to the water pipe of the EGR valve bracket.

Mazda 2. ENGINE COOLANT

CAUTION:

9. Refill the engine coolant to the radiator from the radiator filler neck until engine coolant begins to leak from the blind cap area.

10. Install the blind cap.

11. Install the battery. (See BATTERY REMOVAL/INSTALLATION).

12. Refill the engine coolant from the radiator filler neck until it is close to the top of the radiator filler neck.

13. Refill the engine coolant into the coolant reserve tank up to the FULL mark on the tank.

14. Install the cooling system cap.

CAUTION:

15. Start the engine and warm up the engine by idling.

16. After the engine warms up, perform the following steps. At this time, be careful of the engine coolant temperature to prevent overheating.

NOTE:

  1. Run the engine at 2,500 rpm for 5 min.
  2. Maintain the engine speed at approx. 3,000 rpm for 5 s, and then idle.

    Repeat this procedure four or five times.

17. Stop the engine, and inspect the engine coolant level after the engine coolant temperature decreases. If it is low, repeat steps 12-16.

18. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION).

ENGINE COOLANT PROTECTION INSPECTION

1. Measure the engine coolant temperature and specific gravity using a thermometer and a hydrometer.

CAUTION:

NOTE:

Mazda 2. ENGINE COOLANT

2. Determine the engine coolant protection level by referring to the graph shown in the figure.

Mazda 2. ENGINE COOLANT

ENGINE COOLANT LEAKAGE INSPECTION

WARNING:

1. Inspect the engine coolant level. (See ENGINE COOLANT LEVEL INSPECTION).

2. Remove the cooling system cap.

3. Install the SST and a radiator cap tester to the radiator filler neck.

Mazda 2. ENGINE COOLANT

4. Apply pressure using the radiator cap tester.

CAUTION:

Engine coolant leakage inspection pressure

5. When pressurizing the cooling system, verify that the pressure is maintained.

COOLING SYSTEM CAP INSPECTION

WARNING:

1. Clean the cooling system cap and the sealed part.

2. Inspect the cooling system cap for cracks or everted seal.

3. Attach the cooling system cap to the SST and a radiator cap tester.

Mazda 2. COOLING SYSTEM CAP INSPECTION

4. Hold the cooling system cap downward and apply pressure gradually. Verify that the pressure is held stable for 10 s.

Cooling system cap valve opening pressure

COOLANT RESERVE TANK REMOVAL/INSTALLATION

WARNING:

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

Mazda 2. COOLANT RESERVE TANK REMOVAL/INSTALLATION

  1. Hose
  2. Coolant reserve tank

Coolant Reserve Tank Installation Note

1. Insert the projection on the lower side of the coolant reserve tank into the insertion hole of the radiator cowling, then tighten the coolant reserve tank installation bolt.

Mazda 2. COOLANT RESERVE TANK REMOVAL/INSTALLATION

RADIATOR REMOVAL/INSTALLATION

WARNING:

1. Disconnect the negative battery cable.

2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT).

3. Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION).

4. Remove the cooling fan component. (See COOLING FAN MOTOR REMOVAL/INSTALLATION).

5. Remove in the order indicated in the table.

6. Install in the reverse order of the removal.

7. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT).

8. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION).

Mazda 2. RADIATOR REMOVAL/INSTALLATION

  1. Upper radiator hose
  2. Upper mount rubber bracket
  3. Upper mount rubber
  4. Radiator

Upper Mount Rubber Bracket Removal Note

1. Remove the front bumper fitting bolt as shown in the figure.

Mazda 2. RADIATOR REMOVAL/INSTALLATION

CAUTION:

NOTE:

2. While pressing down the upper mount rubber bracket tab lightly in the direction of the arrow shown in the figure, press the upper mount rubber bracket toward the front of the vehicle.

Mazda 2. RADIATOR REMOVAL/INSTALLATION

3. Remove the upper mount rubber bracket.

Radiator Removal Note

1. Remove the radiator from below the engine compartment.

THERMOSTAT REMOVAL/INSTALLATION

WARNING:

1. Disconnect the negative battery cable.

2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT).

3. Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION).

4. Remove the A/C compressor with hose and pipe still connected. Position the A/C compressor out of the way. (See A/C COMPRESSOR REMOVAL/INSTALLATION).

5. Remove in the order indicated in the table.

6. Install in the reverse order of removal.

7. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT).

8. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION).

Mazda 2. THERMOSTAT

  1. Lower radiator hose (radiator side)
  2. Thermostat cover
  3. Thermostat

Thermostat Installation Note

1. Install the thermostat with the jiggle-pin at the top.

Mazda 2. THERMOSTAT

THERMOSTAT INSPECTION

1. Remove the thermostat. (See THERMOSTAT REMOVAL/INSTALLATION).

2. Visually check that the thermostat valve is closed.

3. Place the thermostat in water.

WARNING:

4. Heat the water and check the following.

Thermostat initial-opening temperature

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