engine coolant MAZDA PROTEGE 1992 Owner's Manual

E
COOLING SYSTEM
INDEX ...................................................... E- 2
OUTLINE .................................................. E- 4
SPECIFICATIONS .................................... E- 4
TROUBLESHOOTING GUIDE ...................... E- 4
ENGINE COOLANT .................................... E- 5
PREPARATION ....................................... E- 5
INSPECTION ..........................................
REPLACEMENT ...................................... :z ;
RADIATOR CAP ........................................
PREPARATION ....................................... ;I ;
INSPECTION .......................................... E- 7
RADIATOR ............................................... E- 8
REMOVAL / INSTALLATION ...................... E- 8
INSPECTION .......................................... E- 9
THERMOSTAT .......................................... E- 9
REMOVAL / INSTALLATION ...................... E- 9
INSPECTION .......................................... E- 9
WATER PUMP .......................................... E-l 1
REMOVAL / INSTALLATION ...................... E-l 1
ELECTRIC COOLING FAN SYSTEM ............ E-13
SYSTEM CIRCUIT .................................... E-l 3
SYSTEM INSPECTION .............................. E-14
FAN MOTOR ............................................. E-14
INSPECTION .......................................... E-l 4
REPLACEMENT ...................................... E-l 5
WATER THERMOSWITCH .......................... E-l 8
REMOVAL / INSTALLATION ...................... E-18
INSPECTION .......................................... E-l 8
RADIATOR THERMOSWITCH ..................... E-l 7
REMOVAL I INSTALLATION ...................... E-17
INSPECTION .......................................... E-l 7
FAN RELAY .............................................. E-l 8
REMOVAL I INSPECTION .......................... E-l 8
INSPECTION .......................................... E-l 8
23UOEX-001

INDEX
B6 SOHC AND BP SOHC
COOLANT RESERVOIR
@ ENGINE COOLANT
TOTAL CAPACITY
MTX: 5.0 liters (5.3 US qt, 4.4 Imp qt)
ATX: 6.0 liters (6.3 US qt, 5.3 Imp qt)
1. Engine coolant 6. Electric cooling fan system
23UOEX-00
inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E- 5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E-
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
page E- 2. Radiator cap
7
3. Radiator
Removal I Installation . . . . . . . ,.......... page E- 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E- 9
4. Thermostat
Removal / Installation . . . . . . . . . . . . . . . . . . page E- 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E- 9
5. Water pump
Removal / Installation ....t___.......... page E-i 1
System
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Water thermoswitch
Removal / Installation . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. Radiator thermoswitch (BP ATX) System
Removal I Installation . . . . . . . . . . . . . . . . . inspection . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IO. Fan relay
7. Fan motor
Removal / Inspection . . . . . . . . . . . . . . . . . page E-13
page E-14
page E-14
page E-15
page E-16
page E-16
page E-17
page E-l 7
page E-18 ..--’
E-2

E
BP DOHC
-a TO HEATER
&$ No.1 RELAY
COOLANT ~~ESERVOI~~
@ ENGINE COOLANT
TOTAL CAPACITY
MTX: 5.0
liters (5.3 US qt, 4.4 Imp qt)
ATX: 6.0 liters (6.3 US qt, 5.3 Imp qt)
23UOEX-00
1. Engine coolant
6. Electric cooling fan system
Inspection ...................................
page E- 5 System circuit
.............................
page E-l 3
Replacement ...............................
page E-
6 System inspection
....................... page E-14
2. Radiator cap
7. Fan motor
Inspection ................................... page E- 7
Inspection ...................................
page E-14
3. Radiator
Replacement..
............................. page E-i 5
Removal / Installation..
................
page E-
8 8. Water thermoswitch
Inspection
.................. ................................... page E- 9 Removal / Installation
page E-16
4. Thermostat
Inspection ...................................
page E-l 6
Removal I Installation
.................. page E- 9 9. Radiator thermoswitch (ATX)
Inspection
.................. ...................................
page E- 9 Removal I Installation
page E-l 7
5. Water pump
Inspection
...................................
page E-l 7
Removal / Installation ..................
page E-i 1 10. Fan relay
Inspection ...................................
page E-l 8
E-3

ENGINE COOLANT E
ENGINE COOLANT
PREPARATION
SST
49 9200 145
For 49 9200 146
For
inspection of inspection of
cooling system Adapter A cooling system
pressure (Part of pressure
49 9200 145)
05UOEX-00
INSPECTION
Warning
l Never remove the radiator cap while the engine is
hot.
l Wrap a thick cloth around the cap when removing it.
l When removing the radiator cap, loosen it slowly
to the first stop until the pressure in the radiator is
released, and then remove it.
03UOEX~006
Coolant Level (Engine cold)
1. Verify that the coolant level is near the radiator filler neck.
2. Remove the coolant level gauge and check the coolant level.
Coolant Quality
1. Verify that there is no buildup of rust or scale around the
radiator cap or radiator filler neck.
2. Verify that coolant is free of oil. Replace the coolant if
necessary.
Coolant Leakage
1. Connect a radiator tester (commercially available) and the
SST to the radiator filler neck.
2. Apply
103 kPa (1.05 kg/cm2, 15 psi) pressure to the
system.
3. Verify that the pressure is held.
If not, check for coolant leakage.
E-5

E ENGINE COOLANT
SPECIFIC
GRAVITY COOLANT PROTECTION
l.OOd ’ ’ I I I I I
0, I I
-10 0 i 10 20 30 40 50 60
70 60 90
(14) (32) (50) (66) (66)(104)(122)(140)(158~176)(194)
COOLANT TEMPERATURE OC (OF)
Coolant Protection
Caution
l Do not use alcohol- or methanol-based coolant.
l Use only soft (demineralized) water in the coolant
mixture.
1. Measure the coolant temperature and specific gravity with
a thermometer and a hydrometer.
2. Determine the coolant protection by referring to the graph
shown.
If the coolant protection is not proper, add water or coolant.
Antifreeze solution mixture percentage
~1
05UOEX-010
REPLACEMENT
Warning
l Never open the radiator cap while the engine is hot.
l Wrap a thick cloth around the cap when loosening.
. Use caution when draining hot coolant.
Caution ..-
l Do not use alcohol- or methanol-based coolant.
l Use only soft (demineralized) water in the coolant
mixture.
1. Remove the radiator cap and loosen the drain plug.
2. Drain the coolant into a suitable container.
3. Flush the cooling system with water until all traces of color
are gone; then let the system drain completely.
4. Install the drain plug.
5. Fill with the proper amount and mixture of ethylene glycol
based coolant by referring to the table above.
Coolant capacity
MTX: 5.0 liters (5.3 US qt, 4.4 Imp qt)
ATX: 6.0 liters (6.3 US qt, 5.3 Imp qt)
6. Run the engine with the radiator cap removed until the up-
per radiator hose is hot.
7. With the engine idling, add coolant to the radiator until it
reaches the bottom of the filler neck.
8. Install the radiator cap.
03UOEX-010 -
E-6

E RADIATOR
RADIATOR
REMOVAL / INSTALLATION
Caution
l Position the hose clamp in the original location on the hose, and squeeze the clamp lightly
with large pliers to ensure a good fit.
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal.
7.8-11 N.m (80-110 cm-kg, 69-95 in-lb)
-...__--- --- i
771 InFu.nnc; cvyILII ..,.,..
6. Oil cooler hose (ATX)
7. Radiator bracket
8. Radiator
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page E-9
9. Cooling fan and radiator cowling assembly 1. Resonance chamber
2. Cooling fan connector
3. Radiator thermoswitch connector (BP ATX)
4. Coolant reservoir hose
5. Radiator hose i
Y’
E-8

RADIATOR, THERMOSTAT t
THERMOSTAT
REMOVAL / INSTALLATION INSPECTION
Check for the following and repair or replace as necessary.
1. Cracks, damage, and water leakage.
2. Bent fins (repair with a screwdriver).
3. Distorted or bent radiator inlet.
Steps After Installation
1. Fill the radiator with the specified amount and type of en-
gine coolant. (Refer to page E-6.)
2. Connect the negative battery cable.
3. Start the engine and check for leaks.
Caution
l Position the hose clamp in the original location on the hose, and squeeze the clamp lightly
with large pliers to ensure a good fit.
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal.
SOHC AND BP SOHC : \,
19-26 N&6.9-2.6 m-kg, 14-19 ft-lb) 19-26 N-m (l.S--2&m-kg, 14-Wft-lb)
23UOEX-006
1. Water thermoswitch connector
2. Radiator hose upper
3. Thermostat cover
4. Thermostat gasket 5. Thermostat
Inspection . . . . .., .., ,.. ,.. . . . ,.. . . . . . . . . . . . . . . . . . . . . . . below
Installation Note ..,....................... page E-10
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . .
page E-10
INSPECTION
1. Visually check that the thermostat valve is airtight.
2. Place the thermostat and a thermometer in water.
3. Heat the water and check the following:
Initial-opening temperature
Main: 86.5-89.5°C (188-193OF)
Sub : 83.5-86.5OC (182-188OF)
Full-open temperature: 1 OOOC (212OF)
Full-open lift
OSUOEX-019
Main: 8.0mm (0.31 In) min.
Sub : 1.5mm (0.06 in) min.
E-9

E THERMOSTAT
Installation Note JIGGLE PIN Thermostat
6 8 8
1. Install the thermostat into the cylinder head with the jiggle
pin at the top. ..__
Thermostat gasket
1. Install a new gasket with the seal print side facing the cylin-
der head.
03UOEX-014
Steps After Installation
1. Fill the radiator with the specified amount and type of engine coolant. (Refer to page E-6.)
2. Connect the negative battery cable,
3. Start the engine and check for leaks.
03UOEX-015
.-
E-IO

WATER PUMP WATER PUMP
E
REMOVAL / INSTALLATION
Caution
l Do not disassemble the water pump. If a problem is found, replace the pump as a Unit.
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. Install in the reverse order of removal.
B6 SOHC AND BP SOHC
83, t B6, BP SOHC
I
I
L-----------------_-- ------- -1
/ \/
19-26 (1.9-2.6, 14-19) LVVVLI. YY,
1. Timing belt 4. Water pump assembly
Service ., . . .., ,, ., . . . . . ,. ,.,. ., ,., . . ,,.... . . . . , Section Bl Inspect for cracks, damaged mounting
2. Water inlet pipe
and gasket surface, bearing condition, and leakage
3. Water bypass pipe and O-ring 5. Water pump gasket
E-l 1

BP DOHC
L 7.8-11 N-m (60-110 cm-kg, 69-95 in-lb)
E WATER PUMP
157-167
I
(W-17, 116-123) I
I
/
I
I
I
---N-w------
---------------
----_---_
-I
N.m (m-kg, ft-lb) 1
^^, *--., ^^^
1. Timing belt
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5. Water pump assembly
B2
2. Water inlet pipe and gasket Inspect for cracks, damaged mounting
3. Water bypass pipe and O-ring surface, bearing condition, and leakage
4. Oil dip stick pipe bracket 6. Water pump gasket
Steps After Installation
1. Fill the radiator with the specified amount and type of engine coolant. (Refer to page E-6.)
2. Connect the negative battery cable,
3. Start the engine and check for leaks.
03UOEX-018
E-12