Do not open the cooling system while it is hot or while the engine is running.

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Garry McLaughlin
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1 Engine And Radiator 2003 Mazda B L Eng VIN D Base Print Date: 1/4/2019 WARNING: Do not open the cooling system while it is hot or while the engine is running. 1. Drain the cooling system. See ENGINE COOLANT REPLACEMENT - 2.3L. 2. Remove the thermostat. 3. Install the thermostat housing without the thermostat. NOTE: 1. Refer to the cooling system Flusher Manufacturer's Operating Instructions for specific vehicle hook-up. 4. Use an appropriate cooling system Flusher to flush the engine and radiator. Use premium cooling system flush. 5. Install the thermostat. 6. Backflush the heater core. 7. Fill the cooling system. See ENGINE COOLANT REPLACEMENT - 2.3L RADIATOR REMOVAL/INSTALLATION - 2.3L Removal 1. Drain the cooling system. See ENGINE COOLANT REPLACEMENT - 2.3L. 2. Remove the plastic cap from the top of the radiator channel. 1/12

2 Fig 1: Removing Plastic Cap From Top Of Radiator Channel 3. Disconnect the coolant overflow hose from the radiator, position the hose away from the radiator. 2/12

3 Fig 2: Disconnecting Coolant Overflow Hose 4. Disconnect the upper radiator hose. 3/12

4 Fig 3: Disconnecting Upper Radiator Hose 5. Remove the cooling fan and shroud. See ELECTRIC COOLING FAN REMOVAL/INSTALLATION - 2.3L. 6. Disconnect the lower radiator hose. 4/12

5 Fig 4: Disconnecting Lower Radiator Hose 7. Remove the bolts, tilt the radiator back and lift it directly upward. 5/12

6 Fig 5: Removing Bolts Installation 1. Position the radiator into the engine compartment and install the bolts. 6/12

7 Fig 6: Installing Radiator Into Engine Compartment NOTE: 1. Reinstall the constant tension clamp in the same position from which it was removed. 2. Install the lower radiator hose to the radiator. 7/12

8 Fig 7: Installing Lower Radiator Hose 3. Install the cooling fan and shroud. See ELECTRIC COOLING FAN REMOVAL/INSTALLATION - 2.3L. NOTE: 1. Reinstall the constant tension clamp in the same position from which it was removed. 4. Install the upper radiator hose to the radiator. 8/12

9 Fig 8: Installing Upper Radiator Hose 5. Position the coolant overflow hose in the channel on top of the radiator, then connect the hose to the radiator. 9/12

10 Fig 9: Installing Coolant Overflow Hose 6. Install the plastic cap on the top of the radiator channel. 10/12

11 Fig 10: Installing Plastic Cap On Top Of Radiator Channel 7. Fill the cooling system. See ENGINE COOLANT REPLACEMENT - 2.3L WARNING: 1. Do not stand in line with or near the engine cooling fan blade when revving the engine. 8. Operate the engine for several minutes and check the hoses and connections for leaks. RADIATOR LEAK TEST INSPECTION - 2.3L CAUTION: Never leak-test an aluminum radiator in the same water that copper/brass radiators are tested in. Flux and caustic cleaners may be present in the cleaning tank and they will damage aluminum radiators. NOTE: 11/12

12 Always install plugs in the oil cooler fittings before leaktesting or cleaning any radiator. Clean the radiator before leak-testing to avoid contamination of the tank. 1. Remove radiator. 2. Leak-test the radiator in clean water with 138 kpa (20 psi) air pressure. RADIATOR PRESSURE TEST INSPECTION - 2.3L 1. Remove the radiator cap. Fill the radiator as needed. Connect a radiator tester (commercially available) to the radiator filler neck. CAUTION: 1. Do not pressurize the cooling system beyond 102 kpa (14.9 psi). 2. Pump the cooling system to a maximum of 102 kpa (14.9 psi) and hold for 2 minutes. If the pressure drops within this time, inspect for leaks and repair as required. 12/12

Chapter 39 Cooling System Fundamentals Test

TERRY FOX AUTOMOTIVE Chapter 39 Cooling System Fundamentals Test When you are done this test guess what you think you will receive for a mark below. If you are within 2 of your actual score you will receive