Mazda Protege 5. Manual — part 135

COOLING SYSTEM

01–12–4

ENGINE COOLANT LEAKAGE INSPECTION

A3U011215001W04

1. Inspect the coolant level.
2. Remove the radiator cap.
3. Connect a radiator cap tester and the SST to the

radiator filler neck.

Caution

••••

Applying more than 123 kPa {1.25 kgf/
cm

2

, 17.8 psi} can damage the hoses,

fittings, and other components, and
cause leaks.

4. Apply pressure to the radiator.

Pressure

123 kPa {1.25 kgf/cm

2

, 17.8 psi}

5. Verify that the pressure is held.

•

If not, inspect the system for coolant leakage.

End Of Sie

RADIATOR CAP INSPECTION

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Warning

••••

Never remove the radiator cap while the engine is running, or when the engine and radiator are
hot. Scalding 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 while still using the cloth, turn
it, and remove it.

1. Attach the radiator cap to a radiator cap tester

with the SST. Apply pressure gradually.

2. Verify that the pressure becomes stable within the

specification.

•

If the pressure is held for 10 s, the radiator
cap is normal.

Pressure

94—122 kPa {0.95—1.25 kgf/cm

2

, 13.5—17.7

psi}

End Of Sie

RADIATOR REMOVAL/INSTALLATION

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1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See 01–12–2 COOLING SYSTEM SERVICE WARNINGS.) (See 01–12–3 ENGINE

COOLANT REPLACEMENT.)

3. Remove the fresh air duct.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.

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COOLING SYSTEM

01–12–5

01–12

.

End Of Sie

THERMOSTAT REMOVAL/INSTALLATION

A3U011215171W01

1. Disconnect the negative battery cable.
2. Remove the fresh air duct.
3. Remove the air cleaner. (ZM model)
4. Drain the engine coolant. (See 01–12–2 COOLING SYSTEM SERVICE WARNINGS.) (See 01–12–3 ENGINE

COOLANT REPLACEMENT.)

5. Remove in the order indicated in the table.

X3U112WA5

1

Upper radiator hose

2

Cooling fan motor connector, condenser fan motor
connector

3

Lower radiator hose

4

Condenser fan

5

Cooling fan

6

Oil hose (ATX)
(See 05–17–41 OIL COOLER REMOVAL/
INSTALLATION)

7

Radiator

1

Thermostat cover

2

Thermostat cover gasket
(See 01–12–7 Thermostat Cover Gasket Installation
Note)

3

Thermostat
(See 01–12–6 Thermostat Installation Note)

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COOLING SYSTEM

01–12–6

6. Install in the reverse order of removal.

Thermostat Installation Note
ZM

1. Install the thermostat into the cylinder head with

the jiggle pin at the top.

FS

1. Install the thermostat into the thermostat case

with the jiggle pin and projection at the top.

2. Install the thermostat into the thermostat case,

aligning the projection on the gasket to the
thermostat case.

1

Lower radiator hose

2

Thermostat cover

3

Thermostat
(See 01–12–6 Thermostat Installation Note)

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COOLING SYSTEM

01–12–7

01–12

Thermostat Cover Gasket Installation Note
ZM

1. Install a new gasket with the seal ring side facing

the cylinder head.

End Of Sie

THERMOSTAT INSPECTION

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1. If the gasket of the thermostat is damaged,

replace the thermostat assembly. (FS model)

2. Visually check that the thermostat valve is closed.
3. Place the thermostat and a thermometer in water.

Warning

••••

During inspection, the thermostat and
water are extremely hot and they can
cause severe burns. Do not touch the
thermostat and water directly.

4. Heat the water and check the following.

•

If not as specified, replace the thermostat.

End Of Sie

X3U112WAA

Item

Engine

ZM

FS

Initial-opening temperature

83.5—88.0

{183—190}

80—84

{176—183}

(

°

C {

°

F})

Full-open temperature

100 {212}

95 {203}

(

°

C {

°

F})

Full-open lift

(mm {in})

8.5 {0.33} min.

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