ELECTRIC WATER PUMP No.1 REMOVAL/INSTALLATION [PYUL]SM3357728
ELECTRIC WATER PUMP No.1 REMOVAL/INSTALLATION [PYUL]

id01121a810900


D-code

• 15711

Open Capsule Cover

1.Open in the order indicated in the table.
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Step

Part name
1
Rotating fastener
(See Opening capsule cover note)
(See Closing capsule cover note)
2
Capsule cover
(See Opening capsule cover note)
(See Closing capsule cover note)
3
Clip
(See Opening capsule cover note)
(See Closing capsule cover note)


Opening capsule cover note

1.Open the capsule cover as shown in the figure.
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Content
Servicing procedure


Closing capsule cover note

1.Close the capsule cover as shown in the figure.
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Content
Servicing procedure


Remove Cover Assembly (Passenger's Side)

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Cover assembly
(See Cover assembly removal note.)


Cover assembly removal note

Note
• Release the clips according to the lock/unlock mark on the cowl grille cover.

1.Remove the cover assembly as shown in the figure.

• The figure shows the left side (same as right side).
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Content
Servicing procedure


Disconnect Negative Lead-Acid Battery Terminal


With e-SKYACTIV PHEV

Warning
• Before removing the SRS air bag system-related parts, always disconnect the negative lead-acid battery terminal and wait for 1 min or more to allow the back-up power supply to deplete its stored power.
• Contact with the positive lead-acid battery terminal could cause electrocution due to a short circuit and result in serious injury or death, or damage to vehicle parts. Do not contact the positive lead-acid battery terminal when performing the procedure.
Caution
• If the nut for the current sensor is loosened with the negative lead-acid battery terminal connected to the lead-acid battery, excessive torque will be applied to the negative lead-acid battery terminal and the lead-acid battery terminal will be damaged. When removing the negative lead-acid battery terminal and current sensor, be careful not to damage the lead-acid battery terminal.
• Be careful not to contact the positive lead-acid battery terminal.

1.Verify that the charge cable is not connected to the charging port.

• If the charge cable is connected to the charging port, remove the charge cable.

2.Keep the driver's door open.

3.Keep the hood open.

4.Keep the main power switched ON (READY on) for 3 s or more.

5.Switch the main power OFF and start measuring the time since the main power was switched OFF using a stopwatch.

Caution
• If the cooling fan does not stop after 5 min have elapsed since the main power was switched OFF, wait until it stops.
• If the [Battery cooling] operation notification is displayed on the center display, do not make a selection and leave it as it is.

6.Switch the main power OFF and wait for 5 min.

Warning
• Before servicing after disconnecting the negative lead-acid battery terminal, wait for 1 min or more.
Caution
• If the time since the main power was switched OFF in Step 5 to the disconnection of the negative lead-acid battery terminal exceeds 25 min, perform the procedure from Step 3 again.
Note
• In order to prevent it from falling off, the negative lead-acid battery terminal nut cannot be removed.
• After the negative lead-acid battery is disconnected, there is no restriction on opening/closing the door.

7.Disconnect the negative lead-acid battery terminal within 25 min from switching the main power OFF in Step 5 using the following procedure.

(1)Disconnect the current sensor connector.
(2)Disconnect the negative lead-acid battery terminal.
• When disconnecting a negative lead-acid battery terminal with deformed plastic, expand the gap of the negative lead-acid battery terminal using a flathead screwdriver, and remove the terminal.
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Content
5 N·m {51 kgf·cm, 44 in·lbf}


Without e-SKYACTIV PHEV

Warning
• Before removing the SRS air bag system-related parts, always disconnect the negative battery terminal and wait for 1 min or more to allow the back-up power supply to deplete its stored power.
• Contact with the positive battery terminal could system may electrocution due to a short circuit and result in serious injury or death, or damage to vehicle parts. Do not contact the positive battery terminal when performing the procedure.
Caution
• Do not perform servicing for a long period ( 10 min or more) with the engine switch ON (engine stop).

1.Connect the M-MDS to the DLC-2.

2.Turn ON the engine switch (engine stop).

3.Verify the[BATT_SOC] value using the M-MDS data logger function.

4.Record the [BATT_SOC] value.

[BATT_SOC] value is less than 75%
• Inspect the battery.
[BATT_SOC] value is 75% or more
• Go to the next step.

5.Turn OFF the engine switch.

Caution
• If the nut for the current sensor is loosened with the negative battery terminal connected to the battery, excessive torque will be applied to the negative battery terminal and the battery terminal will be damaged. When removing the negative battery terminal and current sensor, be careful not to damage the battery terminal.
• Be careful not to contact the positive battery terminal.

6.Disconnect the current sensor connector.

Note
• The positive battery terminal nut cannot be removed to prevent it from falling off.

7.Disconnect the negative battery terminal.

• When disconnecting the plastic deformed negative battery terminal, expand the gap of the negative battery terminal using a flathead screwdriver for removal.
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Content
5 N·m {51 kgf·cm, 44 in·lbf}


Remove Front Under Cover No.2

1.Remove using the procedure shown in the figure.
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Step

Part name
1
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
2
Fastener
—
3
Front under cover No.2
—


Remove Front Under Cover No.1

1.Remove using the procedure shown in the figure.
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Step

Part name
1
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
2
Screw
2 N·m {20 kgf·cm, 17 in·lbf}
3
Fastener
—
4
Front under cover No.1
—


Drain EV System Coolant

Warning
• The EV system is hot immediately after driving and charging, and can cause severe burns. Turn off the EV system and wait until it is cool before performing the servicing.
• If the cooling system cap is removed while the EV system is hot, hot coolant may be ejected, causing severe burns or injury. Perform the removal of the cooling system cap when the EV system is cool.
• When removing the cooling system cap, cover the cooling system cap with a clean cloth and remove it slowly.
• The cooling fan may suddenly start operating regardless of the main power switch position. Keep hands and tools away from the cooling fan even if the cooling fan is not operating to prevent injury, or damage to the cooling fan. When servicing the cooling fan or parts near the cooling fan, ensure the following.
― Do not perform charging
― Do not select high voltage battery cooling on center display after EV system stops
― Do not open/close doors frequently with main power switched OFF
― Access connected vehicle maintenance mode (MyMazda App connected vehicle)
― Cancel climate control timer
Note
• If the [FL22] mark is shown on or near the cooling system cap, use Mazda Genuine FL22 EV system coolant.
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• FL22 type EV system coolant is shipped as a diluted solution. Use the solution as is when replacing coolant.

EV system coolant capacity (approx. quantity)

Capacity
9.6 L {10 US qt, 8.4 Imp qt}

1.Remove the cooling system cap.
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1
Cooling system cap

2.Drain the EV system coolant from the coolant reserve tank (sub).
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1
Coolant reserve tank (sub)

3.Remove the drain plug (sub).
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Content
Servicing procedure
1 N·m {11 kgf·cm, 9 in·lbf}
Drain cock gasket

4.Draining the EV system coolant.

5.Install the radiator drain plug (sub).


Remove Driver Side Front Deflector

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Fastener
—
2
Fastener
(See Fastener removal note.)
—
3
Screw
2 N·m {20 kgf·cm, 17 in·lbf}
4
Front deflector
—


Fastener removal note

1.Partially peel back the front over fender upper until the fasteners can be removed as shown in the figure.

• The figure shows the left side (same as right side).
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2.Remove the fasteners.


Remove Electric Water Pump No.1

1.Remove in the order indicated in the table.
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Step

Part name
1
Connector
2
Hose
(See Hose connection note)
3
Hose
(See Hose connection note)
4
Electric water pump No.1


Hose connection note

1.Connect the hose as shown in the figure.
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Hose connection note

1.Connect the hose as shown in the figure.
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Install in Reverse Order of Removal

1.Install in the reverse order of removal.


Add Coolant (Sub) [PYUL] (With e-SKYACTIV PHEV)

1.Add coolant (sub) to the coolant reserve tank up to the F line.
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1
Bottle

Total coolant amount (reference)
6.5 L {6.9 US qt, 5.7 Imp qt}

Perform Battery Condition Initial Setting (i-Stop Setting)

Caution
• If the engine is started with the hood open, i-stop will not operate until the hood is closed and the engine is restarted. (Not system malfunction) If the engine was started with the hood open, switch the ignition OFF, close the hood, and then restart the engine.
Without M Hybrid Boost (With i-stop)
• (i-stop non operation) If the vehicle is brought in with i-stop not operating, the malfunction cannot be resolved by only performing the battery condition initial setting (i-stop setting). Verify the PID BATT_SOC value and if the value is less than 75%, perform a battery inspection. (See BATTERY INSPECTION.)
• If the [BATT_SOC] has not been verified before disconnecting the negative battery terminal, perform the battery condition initial setting (i-stop setting) after performing the battery inspection.
• Directly after connecting the negative battery terminal, a BATT_SOC value of [ 0%] is displayed because the battery charge status is unstable. (It is necessary to leave vehicle for 6 to 48 hours until battery charge status stabilizes)
Note
T3
• If the diesel particulate filter regeneration control is not performed at a traveled distance of 10 km or less, the PCM performs the diesel particulate filter regeneration control while the setting procedure for the battery condition initial setting (i-stop setting) is performed to stabilize the exhaust gas purification. (Regular regeneration control)
• While the regular regeneration control is performed, a condition in which high engine speed is continued for a specified period of time. (Up to 22 min (depends on engine coolant temperature))

Circle: Applicable—: Not applicable

Purpose

Operation

Without M Hybrid Boost (With i-stop)

T3

PYUL
1. Verify that the BATT_SOC value measured when the vehicle is in the shop is 75% or more.
1. Using the M-MDS, verify that the PID [BATT_SOC] value is 75% or more.
O
O
2. In the following cases, perform a battery inspection. (See BATTERY INSPECTION.)
• [BATT_SOC] value is less than 75%
• [BATT_SOC] value cannot be verified
O
O
2. Have the [BATT_SOC] value determined by the PCM.
1. Disconnect the negative battery terminal and wait for 5 min or more. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)
Note
• It is necessary to leave the lead-acid battery undisturbed for or more because the voltage may not be stabilized depending on the battery usage condition and it could cause the PCM to determine the BATT_SOC value incorrectly.
O
O
3. Have the PCM learn the battery condition.
1. Connect the negative battery terminal and wait for 10 s or more. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)
O
O
2. Switch the ignition ON (engine off) and wait between 15 s to 60 s.
O
O
3. Press and hold the i-stop OFF switch for approx.10 s.
O
O
4. Verify that the i-stop warning light (amber) illumination changes to the i-stop indicator light (green) flashing.
• If the i-stop warning light (amber) does not turn off, it is possible that the procedure was performed incorrectly, therefore, perform the procedure again from the beginning.
• If the i-stop warning light (amber) flashes, perform a battery inspection. (See BATTERY INSPECTION.)
O
O
5. Switch ignition OFF.
O
O
6. Close the hood.
O
O
4. Perform idle air control learning.
1. Switch the ignition ON (engine on).
—
O
2. Turn off the following systems to which electrical load is applied.
• Lighting systems such as headlights.
• Climate control system
• Rear window defogger
—
O
3. Warm up the engine completely.
—
O
4. Switch the ignition OFF.
—
O
5. Verify the i-stop control settings.
Perform the following procedure from Step 1 to 5 within 25 s.
O
O
1. Switch the ignition ON (engine off) and within 5 s, press and hold the i-stop OFF switch for 3 s or more.
O
O
2. Verify that the i-stop warning light (amber) is on.
O
O
3. Switch the ignition ON (engine on).
O
O
4. Verify that the i-stop warning light (amber) illumination changes to the i-stop indicator light (green) flashing.
• If the i-stop warning light (amber) illuminates or flashes, perform a battery inspection. (See BATTERY INSPECTION.)
O
O
5. Press and hold the i-stop OFF switch for approx. 3 s.
O
O
6. Wait for 30 s while idling (with no electrical load).
O
O
7. Perform engine racing for a minimum 10 times and a maximum 20 times. Then, wait for 30 s while idling (with no electrical load).
• After the flashing i-stop indicator light (green) turns off, switch the ignition OFF.
• If the i-stop indicator light (green) does not turn off, it is possible that there is a problem with the M Hybrid system, therefore, perform an inspection of the M Hybrid system.
Note
• The flashing i-stop indicator light (green) may turn off early and the i-stop control setting verification may be completed early depending on the battery condition.
—
—
8. Maintain the idling condition (with no electrical load) until the i-stop indicator light (green) flashing turns off.
O
O
9. After the flashing i-stop indicator light (green) turns off, switch the ignition OFF.
O
O
6. Perform an i-stop control operation verification.
1. Switch the ignition ON (engine on).
O
O
2. Accelerate to a vehicle speed of 15 km/h in approx. 5 s without operating the steering wheel.
O
O
3. Stop the vehicle.
O
O
4. Verify that the engine stops and restarts by the i-stop control.
O
O
5. Switch the ignition OFF.
O
O


Bleed Coolant (Sub) Air (With e-SKYACTIV PHEV)

1.Verify that the coolant system cap (sub) is securely closed.

2.Perform the following procedure within 60 s and switch to air bleeding mode.

(1)Switch the main power ON (READY off).
(2)Release and depress the accelerator pedal 5 times.
(3)Release and depress the brake pedal 10 times.
(4)Switch the main power ON (READY on).
(5)Verify that [Air Bleeding Mode] is displayed in the instrument cluster or on the center display.
• If the liquid level in the coolant reserve tank decreases during air bleeding mode and air becomes mixed in, switch the ignition OFF, and then repeat Steps (1) to (5).

3.After completing air bleeding mode, verify the height of liquid surface in the coolant reserve tank.

Coolant (sub) liquid surface is F line or less
• Remove the coolant system cap (sub), replenish the coolant (sub) up to the F line, and switch to air bleeding mode again.
Coolant (sub) liquid surface is F line
• If there is neither no change in the liquid surface nor bubbles in the coolant reserve tank, the air bleeding is completed.
Note
Air bleeding mode cancellation conditions
• Air bleeding mode elapses for 900 s.
• Changes to a position other than the P position.
• Switch the main power OFF.

4.Inspect the coolant (sub).

5.If the coolant (sub) level is low, add coolant (sub) and perform air bleeding again.


Inspect For PHEV Coolant Leakage

Warning
<<High voltage>>
•Always observe the following thoroughly to ensure safety when inspecting or removing/installing parts in the motor compartment. Otherwise, the high voltage circuit may operate on the vehicle regardless of whether or not the main power is switched OFF or ON (READY off or on). If this occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.
―Do not perform normal charging or quick charging
―Access connected vehicle maintenance mode (MyMazda App connected vehicle)
―Cancel climate control timer
Warning
•Always observe the following thoroughly to ensure safety when inspecting or removing/installing parts in the motor compartment. Otherwise, the cooling fan may operate on the vehicle regardless of whether or not the main power is switched OFF or ON (READY off or on). If this occurs, it could cause injuries such as lacerations and from getting caught in the cooling fan.
―Do not perform normal charging or quick charging
―Access connected vehicle maintenance mode (MyMazda App connected vehicle)
―Cancel climate control timer
•The EV system is hot immediately after driving and charging, and can cause severe burns. Turn off the EV system and wait until it is cool before performing the servicing.
•If the PHEV cooling system cap is removed while the PHEV cooling system is hot, hot coolant may be ejected, causing severe burns or injury. Perform the removal of the PHEV cooling system cap when the PHEV cooling system is cool.
•When removing the PHEV cooling system cap, cover the PHEV cooling system cap with a clean cloth and remove it slowly.
Note
•Perform the procedure with the PHEV cooling system cap removed.

1.Install the radiator cap tester to the filling port.
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2.Apply pressure using the radiator cap tester.

Coolant leakage inspection pressure
122.6 kPa{1.148 kgf/cm2, 16.33 psi} [1 min]

3.When pressurizing the radiator, verify that the pressure is maintained.

•If the pressure decreases, repair or replace the location where water is leaking because water leakage can be considered.


Install cooling system cap (sub)

1.Remove in the order indicated in the table.
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Step

Part name
1
Cooling system cap (sub)


Perform Power Liftgate Initialization

Note
• If the negative battery terminal is disconnected with the power liftgate fully opened or half-open, the auto open/close operation of the power liftgate is disabled.

1.Close the power liftgate manually.


Initialize Power Outer Mirror Retract/Return Function

Note
• After reconnecting the negative battery terminal, the power outer mirror retract/return position recognized by the door-electrical supply unit may differ from the power outer mirror retract/return position of the vehicle. For this reason, it may be necessary to initialize the power outer mirror retract/return function.

Power outer mirrors are in returned position

1.Switch the ignition ON (engine off)/switch the main power ON (READY off).

2.Press the power outer mirror retract/return switch to retract the power outer mirrors.

3.Press the power outer mirror retract/return switch again to return the power outer mirrors.

4.Switch the ignition OFF/switch the main power OFF.


Power outer mirrors are in retracted position

1.Switch the ignition ON (engine off)/switch the main power ON (READY off).

2.Press the power outer mirror retract/return switch 2 times to return the power outer mirrors.

3.Switch the ignition OFF/switch the main power OFF.