Cooling System - Coolant Leak From Water Outlet
Bulletin No: 01-026/10Last Issued: 04/23/2010
Subject:
ENGINE COOLANT LEAKAGE FROM WATER OUTLET
BULLETIN NOTE
APPLICABLE MODEL(S)/VINS
2006 - 2008 Mazda3 vehicles (except Mazdaspeed3) with VINS lower than JM1BK3*****187397 (produced before July 1, 2008)
2008 Mazda5 vehicles with VINS lower than JM1 CR******327438 (produced before July 1, 2008)
DESCRIPTION
On some vehicles, the engine coolant may leak from the water outlet. This is caused by the gasket making contact with the corner of the water outlet groove. The shape of the water outlet gasket groove and gasket has now been changed.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
NOTE:
Let the engine cool down before proceding with the repair.
2. Remove the battery and battery tray with PCM. Refer to MS3 online instructions or Workshop Manual section 01-17.
3. Remove the air cleaner case and cover, and move any hoses or wiring harnesses with brackets to the side. Refer to MS3 online instructions or Workshop Manual section 01-13.
4. Drain the engine coolant. Refer to MS3 online instructions or Workshop Manual section 01-12.
5. Remove the hoses attached to the water outlet and move any other hoses or wiring harnesses to the side to remove the four water outlet bolts.
6. Remove the water outlet and replace the gasket with a modified one.
NOTE:
^ Do not allow mineral oil (engine oil, ATF, or fuel) to get on the gasket.
^ Degrease and clean the cylinder head surface and water outlet.
7. Install the water outlet with the four bolts.
Tightening torque: 8.0-11.5 Nm {82-117 kgfcm, 71-101 inlbf}
8. Attach the hoses to the water outlet and place the other hoses and wiring harnesses back into place.
9. Install the air cleaner case and cover, and place the hoses and wiring harnesses with brackets back into place. Refer to MS3 online instructions or Workshop Manual section 01-13.
10. Refill the engine coolant.
11. Install the battery tray with PCM and the battery. Refer to MS3 online instructions or Workshop Manual section 01-17.
12. Verify repair.
PART(S) INFORMATION
WARRANTY INFORMATION
NOTE: