COOLING SYSTEM PIPE REMOVAL/INSTALLATION

id301200001700

Warning

<<High voltage>>

•  If the necessary measures are not taken before servicing an electric vehicle, it could cause electrical shock and result in serious injury or, in the worst case, death. Before servicing the electric vehicle, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and implement the necessary measures. (See HIGH VOLTAGE SERVICE CAUTIONS.)

High Voltage Part Inspection And Removal/Installation Notes

Warning

<<High voltage>>

•  If necessary measures such as wearing the correct protective gear are not taken when inspecting or removing/installing the high voltage parts, it could cause electrical shock and result in serious injury or, in the worst case, death.

•  Before inspecting or removing/installing the high voltage parts, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and [High Voltage Part Inspection and Removal/Installation Notes] of the high voltage system service cautions and implement the necessary measures and preparations. (See HIGH VOLTAGE SERVICE CAUTIONS.) (See HIGH VOLTAGE SYSTEM SERVICE CAUTIONS.)

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

Caution

•  Attach the water pipe and water hose as shown in the figure.

Connection of water pipe and water hose

―  Align the marking on the water pipe with the marking on the water hose.

a30zzw00004195

Connection of vehicle parts and water hose

―  Align the protrusions on the vehicle parts (such as the reserve tank) with the markings on the water hose.

a30zzw00004196

Coolant draining procedure

Cooling System Pipe Removal

1.  Remove using the procedure shown in the figure.

Motor compartment side

a30zzw00007317

1	Upper radiator hose	(See RADIATOR REMOVAL/INSTALLATION.)
2	Lower radiator hose
3	Water hose (coolant reserve tank to DC-DC converter)	(See COOLANT RESERVE TANK REMOVAL/INSTALLATION)
4	Water hose (electric water pump side to electric motor)	(See ELECTRIC MOTOR REMOVAL/INSTALLATION.)
5	Water hose (DC-DC converter to inverter)	(See INVERTER REMOVAL/INSTALLATION.)
6	Water hose (inverter to water pipe (on reduction gear))
7	Water hose (water pipe (on reduction gear) to electric water pump)	(See ELECTRIC WATER PUMP REMOVAL/INSTALLATION.)
8	Water pipe (on reduction gear)	(See Water pipe (floor) removal.) (See Water pipe (floor) installation.)
9	Water hose (water pipe (on reduction gear) to water pipe (on front crossmember))
10	Water hose (water pipe (on front crossmember) to water pipe (on reduction gear))
11	Water pipe (on front crossmember)
12	Water hose (water pipe (on front crossmember) to water pipe (floor))
13	Water hose (water pipe (floor) to water pipe (on front crossmember))

On board charger side

a30zzw00007318

1	Water hose (rear)	(See Water pipe (floor) removal.) (See Water pipe (floor) installation.)
2	Water pipe (floor)

Water pipe (floor) removal

Replacement parts

1.  Verify that the READY indicator on the instrument cluster is not illuminated.

•  If the READY indicator is turned on, switch the main power OFF.

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

3.  Partially peel back the cover.

a30zzw00004019

4.  Remove the service hole cover.

a30zzw00004020

5.  Wear insulating gloves and remove the service plug using the following procedure.

Warning

<<High voltage>>

•  Touching the terminal on the vehicle side can result in serious injury or death from electric shock. For this reason, after removing the service plug, cover the vehicle-side terminals with insulating tape so that they cannot be touched.

•  Do not touch high voltage parts for 10 min after removing service plug. Electric charges may be stored on the condenser for 10 min after the service plug is removed, and touching high voltage parts during that time can result in serious injury or death from electric shock.

•  Service plugs must be removed by workers inspecting/removing/installing high voltage parts. Keep the removed service plug on your person until inspection/removal/installation of the high voltage parts is completed to prevent other workers from accidentally installing the service plug.

Caution

<<High voltage>>

•  After removing the service plug, cover the vehicle side terminals with insulating tape to prevent foreign matter from adhering to them.

•  When you are keeping the service plug on your person, cover the service plug terminals with insulating tape to prevent damage to them.

•  Do not switch the main power ON (READY on) after removing the service plug. If the main power is switched ON (READY on) after removing the service plug, the vehicle may malfunction.

(1)  Slide the lock in the direction of the arrow shown in the figure. (Do not pull out completely)

a30zzw00004021

(2)  Raise the lever.

a30zzw00004502

(3)  Press the area indicated by arrow (1) shown in the figure, release the tabs, and then raise the lever until it is perpendicular.

a30zzw00004503

(4)  Hold the lever and pull the service plug straight up.

a30zzw00007319

6.  After removing the service plug, leave it for 10 min.

7.  Wear insulating gloves and measure the voltage at the high voltage cable connection (junction box No.3 side) using the following procedure.

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

Caution

<<High voltage>>

•  Be careful not to allow foreign matter or water droplets to enter the junction box No.3. Since the junction box No.3 has a high voltage circuit, there is a risk of malfunction if foreign matter or water drops enter it.

•  Remove the terminal cover by pulling it straight up. The terminal cover is fitted with an interlock switch. This interlock switch may be damaged if the terminal cover is removed while being tilted.

•  Do not touch the moisture-proof seal on the terminal cover. If the seal is touched or damaged, replace the terminal cover.

a30zzw00004024

(2)  Remove the terminal cover.

a30zzw00006970

(3)  Measure the voltage at the high voltage cable connection.

Note

•  Use a voltmeter with a measurement range of 450 V DC or more.

a30zzw00004025

―  Verify that the voltmeter indicates 0 V and go to the next step.

8.  Load the vehicle on the auto lift and lift it up.

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

10.  Remove the rear wheel and tire (RH). (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

11.  Remove the rear mudguard (RH). (See MUDGUARD REMOVAL/INSTALLATION.)

12.  Fold the rear seat backs (RH/LH).

13.  Remove the rear package tray. (See REAR PACKAGE TRAY REMOVAL/INSTALLATION.)

14.  Remove the trunk mat. (See TRUNK COVERING REMOVAL/INSTALLATION.)

15.  Remove the trunk board. (See TRUNK BOARD REMOVAL/INSTALLATION.)

16.  Implement the [Coolant Draining Procedure] for the onboard charger removal/installation. (See ONBOARD CHARGER REMOVAL/INSTALLATION.)

17.  Remove the onboard charger water hoses (IN side/OUT side).

a30zzw00007320

18.  Collect the refrigerant. (See REFRIGERANT RECOVERY.)

19.  Remove the gusset. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

20.  Remove floor under cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

21.  Remove the shield.

a30zzw00007321

22.  Disconnect the cooler pipe (high voltage battery side). (See REAR COOLER PIPE REMOVAL/INSTALLATION.)

23.  Remove the high voltage battery. (See HIGH VOLTAGE BATTERY REMOVAL/INSTALLATION.)

24.  Set a tray (volume: approx. 2 L) under the quick release connector at the front part of the water pipe to receive coolant.

25.  Slowly remove the quick release connector at the front part of the water pipe and drain the coolant. (See Quick Release Connector Removal.)

26.  Remove the water hose (rear).

27.  Remove the water pipe (floor).

Water pipe (floor) installation

1.  Install the water pipe (floor).

2.  Install the water hose (rear).

3.  Install the quick release connector. (See Quick Release Connector Installation.)

4.  Press and pull the quick release connector forward/back several times and verify that it is connected securely.

5.  Install the high voltage battery. (See HIGH VOLTAGE BATTERY REMOVAL/INSTALLATION.)

6.  Connect the cooler pipe (high voltage battery side). (See REAR COOLER PIPE REMOVAL/INSTALLATION.)

7.  Install the shield.

a30zzw00007321

8.   Install the onboard charger water hoses (IN side/OUT side).

a30zzw00007320

9.  Move the rear seat backs (RH/LH) to their upright positions.

10.  Wear insulating gloves and install the service plug using the following procedure.

(1)  Insert the service plug as far as it will go.

a30zzw00004026

(2)  Depress the lever completely.

a30zzw00004027

(3)  Slide the lock in the direction of the arrow shown in the figure until the hook is engaged.

a30zzw00004028

11.  Install the service hole cover.

a30zzw00004020

12.  Close the cover.

a30zzw00004029

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

14.  Implement the [Coolant Replenishment Procedure] for the onboard charger removal/installation. (See ONBOARD CHARGER REMOVAL/INSTALLATION.)

15.  Implement the [Air Bleeding Procedure] for the onboard charger removal/installation. (See ONBOARD CHARGER REMOVAL/INSTALLATION.)

16.  Inspect to confirm that there is no coolant leakage at any part. (See COOLANT LEAKAGE INSPECTION.)

17.  Install the trunk board. (See TRUNK BOARD REMOVAL/INSTALLATION.)

18.  Install the trunk mat. (See TRUNK COVERING REMOVAL/INSTALLATION.)

19.  Install the rear package tray. (See REAR PACKAGE TRAY REMOVAL/INSTALLATION.)

20.  Install the rear mudguard (RH). (See MUDGUARD REMOVAL/INSTALLATION.)

21.  Install the rear wheel and tire (RH). (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

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

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

24.  Charge the refrigerant. (See REFRIGERANT CHARGING.)

25.  Perform the air-conditioning system performance test. (See REFRIGERANT SYSTEM PERFORMANCE TEST.)

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

Quick Release Connector Removal

1.  Remove the quick release connector using the following procedure.

(1)  Press the tab on the retainer to detach the quick release connector.

a30zzw00004186

Note

•  The retainer remains attached to the inverter or water pipe even if the quick release connector is disconnected.

(2)  While holding down the retainer tab, pull on the quick release connector and disconnect it.

(3)  Protect the disconnected quick release connector, inverter, and water pipe by wrapping them in plastic to prevent damage or soiling.

Quick Release Connector Installation

1.  Inspect the sealing surface of the inverter and water pipe for damage or deformation.

•  If there is any malfunction, perform replacement.

2.  Install the quick release connector in the order shown in the figure.

a30zzw00004187

3.  Install the quick release connector in the order shown in the figure.