engine MAZDA MODEL 626 2002 Repair Manual

8-13
Maintenance and Care
Owner Maintenance
Form No. 8Q50-EA-01G





Inspecting Coolant Level
Inspect the antifreeze protection and
coolant level in the coolant reservoir at
least once a year —at the beginning of the
winter season—and before traveling
where temperatures may drop below
freezing.
Inspect the condition and connections of
all cooling system and heater hoses.
Replace any that are swollen or
deteriorated.
The coolant should be at full in the
radiator and between the F and L marks
on the coolant reservoir when the engine
is cool. If it
’s at or near L, add enough coolant to
the coolant reservoir to provide freezing
and corrosion protection and to bring the
level to F.
Do not overfill.
If new coolant is required frequently,
consult an Authorized Mazda Dealer.





Changing Coolant
Change coolant according to Scheduled
Maintenance (page 8-3).
Engine Coolant
Hot Engine:A hot engine is dangerous. If the
engine has been running, parts of the
engine compartment can become very
hot. You could be burned. Don ’t
inspect the coolant system or add
coolant when the engine is hot.
WARNING
2.0-liter engine
2.5-liter engine
Radiator coolant will damage paint.
Rinse it off quickly.
• Use only soft (demineralized) water
in the coolant mixture. Water that
contains minerals will cut down on
the coolant ’s effectiveness.
• Don ’t add only water. Always add a
proper coolant mixture.
• The engine has aluminum parts and
must be protected by an ethylene-
glycol-based coolant to prevent
corrosion and freezing.
• DO NOT USE alcohol or methanol
antifreeze. DO NOT MIX alcohol
or methanol with the coolant. This
could damage the cooling system.
• Don ’t use a solution that contains
more than 60 % antifreeze.
This would reduce effectiveness.
CAUTION
CAUTION
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8-14
Maintenance and Care
Owner Maintenance
Form No. 8Q50-EA-01G
For mixture percentage:
To change coolant1. Remove the cooling system cap.
2. Only when the engine is cool, loosen the radiator drain plug and drain the
coolant into a suitable container.
3. With the drain plug loose but not fully removed, flush out the system with
running water.
4. Drain the system completely and retighten the plug.
Protection Volume
Antifreeze solution Wa t e r
Above −16 °C
(3 °F) 35% 65%
Above −26 °C
( − 15 °F) 45 55
Above −40 °C
( − 40 °F) 55 45
Removing the Cooling System Cap:Removing the cooling system cap or
drain plug while the engine is
running or hot is dangerous. This
might lead to cooling system and
engine damage and could result in
serious injury from escaping hot
coolant or steam. Turn off the engine
and wait until it
’s cool. Even then, be
very careful when removing the cap
or drain plug. 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 — still
using a cloth — turn the cap, and
remove it.
WARNING
2.0-liter engine Cooling system cap
Loosen
Tighten
Drain plug
Loosen
Tighten
LoosenTighten
Cooling system cap
Drain plug
2.5-
liter engine
Loosen Tighten
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8-15
Maintenance and Care
Owner Maintenance
Form No. 8Q50-EA-01G
5. Fill the radiator (to the top of the filler neck) and then the coolant reservoir (to
F) with as much ethylene-glycol-based
coolant and water as necessary to
provide protection from freezing and
corrosion.
In extremely cold climates, add the
amount recommended by the coolant
manufacturer.
6. Reinstall the cooling system cap.
7. Run the engine at idle for about 10 minutes.
8. Then do this: •Run the engine at 2,500 rpm for
about 5 minutes.
• Increase the engine speed to 3,000
rpm for about 5 seconds and then
release the accelerator.
• Do this 4 or 5 times.
• Make sure the engine temperature
gauge does not reach the HOT zone.
After turning off the engine, inspect the
drain plug and the water hoses for leaks.
9. After the engine has cooled, remove the cooling system cap and inspect the
coolant level. If it ’s low, repeat steps 5
to 8.
Because this procedure requires technical
expertise, we recommend that it be done
by an Authorized Mazda Dealer.





Inspecting Brake/Clutch Fluid
Level
The brakes and clutch draw fluid from the
same reservoir.
Inspect the fluid level in the reservoir
regularly. It should be kept at MAX.
The level normally drops with
accumulated distance, a condition
associated with wear of brake and clutch
linings. If it is excessively low, have the
brake/clutch system inspected by an
Authorized Mazda Dealer.
NOTE
Mixing green coolant with orange
coolant could decrease the service life
expectancy of the coolant. Use only
genuine Mazda orange colored or
equivalent coolant.
Brake/Clutch Fluid
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8-16
Maintenance and Care
Owner Maintenance
Form No. 8Q50-EA-01G





Adding Brake/Clutch Fluid
If the fluid level is low, add fluid until it
reaches MAX.
Before adding fluid, thoroughly clean the
area around the cap.
Spilled Brake Fluid:Spilled brake fluid is dangerous. If it
gets in your eyes, they could be
seriously injured. If this happens,
immediately flush your eyes with
water and get medical attention.
Brake fluid spilled on a hot engine
could cause a fire. Be careful not to
spill brake fluid on yourself or on the
engine.
Low Brake/Clutch Fluid Levels:
Low brake/clutch fluid levels are
dangerous. Low levels could signal
brake lining wear or a brake system
leak. Your brakes could fail and cause
an accident. If you find a low fluid
level, have the brakes and clutch
inspected.
WARNING• Brake and clutch fluid will damage
painted surfaces. If brake or clutch
fluid does get on a painted surface,
wipe it off immediately.
• Using nonspecified brake and clutch
fluids (page 10-4) will damage the
systems. Mixing different fluids
will also damage them.
If the brake/clutch system
frequently requires new fluid,
consult an Authorized Mazda
Dealer.
CAUTION
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8-17
Maintenance and Care
Owner Maintenance
Form No. 8Q50-EA-01G





Inspecting Power Steering Fluid
Level
Inspect the fluid level at each engine oil
change. Add fluid if necessary; it does not
require periodic changing.
The level must be kept between the HIGH
and LOW marks.
Visually examine the lines and hoses for
leaks and damage.
1. Park on a level surface, well off the
right-of-way, and set the parking brake
firmly.
2. Turn off the engine and allow it to cool. 3. Remove the filler cap and attached
dipstick.
4. Wipe them clean and put them back.
5. Remove again and inspect the level.
6. It must be between HIGH and LOW. Add fluid if necessary.
Don ’t overfill.
If new fluid is required frequently, consult
an Authorized Mazda Dealer.
Power Steering Fluid
To avoid damage to the power steering
pump, don’ t operate the vehicle for
long periods when the power steering
fluid level is low.
NOTE
Use specified power steering fluid
(page 10-4).
CAUTION
High
Low OK
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8-18
Maintenance and Care
Owner Maintenance
Form No. 8Q50-EA-01G





Inspecting Automatic transaxle
Fluid Level
The automatic transaxle fluid level should
be inspected regularly. Measure it as
described below.
The volume of fluid changes with the
temperature. Fluid must be checked at idle
without driving at normal operating
temperature.
1. Park on a level surface and set the
parking brake firmly.
2. Idle the engine about two minutes. Push down on the brake pedal.
3. Move the shift lever through all ranges and set it at P. 4. With the engine still idling, pull out the
dipstick, wipe it clean, and put it back.
5. Pull it out again. The proper fluid level is marked on the
dipstick as follows.
2.0-liter engine
Scale A
When the engine has been running and the
fluid is at normal operating temperature,
about 65 °C (150 °F) to 77 °C (170 °F), the
level must be within the crosshatched area
on the dipstick.
Automatic Transaxle Fluid
(ATF)
• Low fluid level causes transaxle
slippage. Overfilling can cause
foaming, loss of fluid, and transaxle
malfunction.
• Use specified fluid (page 10-4). A
nonspecified fluid could result in
transaxle malfunction and failure.
CAUTION
Sudden Vehicle Movement:Shifting the shift lever without first
depressing the brake pedal is
dangerous. The vehicle could move
suddenly and cause an accident.
Make sure the brake pedal is applied
before shifting the shift lever.
WARNING
A
B
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8-19
Maintenance and Care
Owner Maintenance
Form No. 8Q50-EA-01G
Scale B
When the engine has not been running,
and the outside temperature is above 10°C
(50 °F), the level should be between the
bottom hole on the dipstick and the
bottom of the crosshatched area on the
dipstick.
Fully insert the dipstick. When adding
fluid, make sure the fluid level doesn ’t
pass the crosshatched area on the dipstick. 2.5-liter engine
Fluid hot scale A
When the vehicle has been driven and the
fluid is at normal operating temperature,
about 65
°C (150 °F), the level must be
between Full and Low.
Fluid cold scale B
When the engine has not been running
and the outside temperature is about 20 °C
(70 °F), the level must be between Full and
Low.
•
Use scale B only as a reference.
• If outside temperature is lower than
about 10 °C (50 °F), start the engine
and inspect the fluid level after the
engine reaches operating
temperature.
• If the vehicle has been driven for an
extended period at high speeds or in
city traffic in hot weather, inspect
the level only after stopping the
engine and allowing the fluid to
cool for 30 minutes.
NOTE
Inspect both sides of the dipstick for
accurate reading.
CAUTION
•Use the cold scale only as a
reference.
• If outside temperature is lower than
about 20 °C (70 °F), start the engine
and inspect the fluid level after the
engine reaches operating
temperature.
• If the vehicle has been driven for an
extended period at high speeds or in
city traffic in hot weather, inspect
the level only after stopping the
engine and allowing the fluid to
cool for 30 minutes.
A
B
CAUTION
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8-21
Maintenance and Care
Owner Maintenance
Form No. 8Q50-EA-01G
All moving points of the body, such as
door and hood hinges and locks, should
be lubricated each time the engine oil is
changed. Use a nonfreezing lubricant on
locks during cold weather.
Make sure the engine hood’s secondary
latch keeps the hood from opening when
the primary latch is released. A viscous paper air filter fits inside the air
cleaner housing, as shown. It
’s been
specially treated and should not be
cleaned and reused. Replace it when
necessary.





Replacing the Air Filter
1. Unfasten the clamps.
Body LubricationAir Filter
Don ’t drive without an air filter. This
could result in excessive engine wear.
NOTE
If the vehicle is operated in very dusty
or sandy areas, replace the filter more
often than recommended intervals.
CAUTION
Clamp
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8-30
Maintenance and Care
Owner Maintenance
Form No. 8Q50-EA-01G
Yo u r M a z d a’s headlights have replaceable
halogen bulbs.




Replacing a Headlight Bulb
1. Make sure the headlight switch is off.
2. Lift the hood and find the bulb in the
rear of the headlight body.
3. 2.5-liter engine Remove the bolts and the coolant
reservoir.
4. Detach the electrical connector from the bulb by squeezing the tabs and
pulling it to the rear.
Handling Halogen Bulbs:When a halogen bulb breaks, it is
dangerous. These bulbs contain
pressurized gas. If one is broken, it
will explode and serious injuries
could be caused by the flying glass.
If the glass portion is touched with
bare hands, body oil could cause the
bulb to overheat and explode when lit.
Never touch the glass portion of the
bulb with your bare hands and always
wear eye protection when handling or
working around halogen bulbs.
Children and Halogen Bulbs:
Playing with a halogen bulb is
dangerous. Serious injuries could be
caused by dropping a halogen bulb or
breaking it some other way.
Always keep halogen bulbs out of the
reach of children.
WARNING
Do not touch the glass surface
Bolts
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8-37
Maintenance and Care
Owner Maintenance
Form No. 8Q50-EA-01G





Fuse Panel Description
Fuse block (Engine compartment)
DESCRIPTION FUSE
RATING PROTECTED
COMPONENT
1EGI INJ 30A Fuel injection
system
2 DEFOG 40A Rear window
defroster
3 —— —
4 MAIN 100A For protection of
all circuits
5 IG KEY 30A RADIO,
SUNROOF,
TURN, METER, ENGINE,
POWER
WINDOW,
WIPER fuses,
Ignition system
6 HEATER 40A Heater, Air
conditionerDESCRIPTION FUSE
RATING PROTECTED
COMPONENT
7 BTN 40A TAIL, STOP,
ROOM, DOOR LOCK,
HAZARD,
POWER SEAT fuses
8 COOLING
FA N 30A Cooling fan
9 AD FAN 30A Additional fan
10 (ABS) 60A Antilock brake
system
11 TAIL 15A Taillights,
Parking lights, Dashboard
illumination,
License plate
lights, Switches illumination
12 HORN 15A Horn
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