ELECTRIC WATER PUMP REMOVAL/INSTALLATION

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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 normal charging or quick 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

―  Operate center display and turn off battery heater operation

Coolant draining procedure

Note

•  Record the amount of drained coolant as a reference when adding coolant.

Replacement part

1.  Load the vehicle on the auto lift so that it can be lifted up.

2.  Remove front under cover No.1. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.)

3.  Remove the seal cover. (See SEAL COVER REMOVAL/INSTALLATION.)

4.  Remove the cooling system cap.

5.  Remove front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

6.  Remove the clips and remove the insulator shown in the figure.

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7.  Remove the drain plug on the rear side of the motor shown in the figure and drain the coolant.

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8.  After completely draining the coolant, tighten the drain plug.

Electric Water Pump Removal/Installation

Note

•  Record the amount of drained coolant as a reference when adding coolant.

1.  Disconnect the negative lead-acid battery terminal. (See NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the breather hose clip of the transaxle from the water hose and set the breather hose aside.

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3.  Place a clean cloth around the plug shown in the figure so that coolant does not flow out onto places such as the motor case.

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4.  Remove the plug.

5.  Remove the water hose (onboard charger side) shown in the figure from the water pipe (on deceleration mechanism).

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6.   Install the plug.

7.  Prepare a drainage receptacle (volume: approx. 0.5 L) under the connection area of the water hose (motor side) shown in the figure, slowly remove the water hose (motor side) from the electric water pump, and then drain the coolant. (See Water Hose (Electric Motor Side) Installation Note.)

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8.  Remove using the procedure shown in the figure.

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1	Connector
2	Bolt
3	Electric water pump component
4	Water hose (on board charger side)(See Water Hose (On Board Charger Side) Installation Note.)
5	Short-cord
6	Nut
7	Bracket
8	Electric water pump

Note

•  Secure the water hose (onboard charger side) near the DC-DC converter without connecting the water pipe (on deceleration mechanism).

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9.  Install in the reverse order of removal.

Coolant Replenishment Procedure

1.  Remove the coolant reserve tank installation nuts.

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2.  Remove the coolant reserve tank outlet hose from the DC-DC converter.

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3.  Tilt and secure the coolant reserve tank so that the coolant reserve tank outlet hose is pointed upward.

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4.  Using a commercially-available bottle (volume: approx. 0.5 L), slowly add coolant to the coolant reserve tank.

Note

•  To prevent air infiltration, add approx. 0.5 L for 1 min.

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5.  Stop adding coolant if it begins accumulating in the coolant reserve tank.

6.  Install the coolant reserve tank outlet hose.

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Note

•  Because coolant will overflow from the outlet hose, install the coolant reserve tank lower than the DC-DC converter.

7.  Install the coolant reserve tank installation nuts.

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8.  Using a commercially-available bottle (volume: approx. 0.5 L), add coolant to the water pipe (on deceleration mechanism).

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9.  Using a commercially-available bottle (volume: approx. 0.5 L), add coolant to the water hose (onboard charger side).

Note

•  Because coolant may overflow from the water hose when installing it, lower the water hose to the side of the inverter and add coolant.

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10.  Install the water hose (onboard charger side).

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11.  Using a commercially-available bottle (volume: approx. 0.5 L), add coolant to the F line on the coolant reserve tank.

Note

•  To prevent air infiltration, add approx. 0.5 L for 1 min.

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12.  After adding coolant to the F line on the coolant reserve tank, add an additional 0.26 L.

13.  Install the cooling system cap.

Air Bleeding Procedure

1.  Inspect each area for coolant leakage. (See COOLANT LEAKAGE INSPECTION.)

2.  Install the insulator.

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3.  Install front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

4.  Lower the vehicle to the ground and adjust the coolant amount to the F line on the coolant reserve tank.

5.  Install the seal cover. (See SEAL COVER REMOVAL/INSTALLATION.)

Water Hose (Electric Motor Side) Installation Note

1.  Attach the water hose (electric motor side) markings to the protrusions on the electric water pump as shown in the figure.

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Water Hose (On Board Charger Side) Installation Note

1.  Attach the water hose (on board charger side) markings to the protrusions on the electric water pump as shown in the figure.

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