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Home >> Mazda >> 2024 >> CX-90 Turbo Select >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Intake-Air System And Turbocharger (VIN C & VIN D) >> Water-Cooled Charge Air Cooler Removal/Installation [H3T] >> Water-cooled Charge Air Cooler Removal/Installation >> Notes

Water-cooled Charge Air Cooler Removal/Installation: Notes

WARNING:
  • Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
  1. Remove the front under cover No. 2. (See REMOVE FRONT UNDER COVER NO. 2 .)
  2. Remove the front under cover No. 1. (See REMOVE FRONT UNDER COVER NO. 1 .)
  3. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [H3T] .)
  4. Drain the water-cooled charge air cooler coolant. (See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT [H3T] .)
  5. Remove the wheel and tire. (See WHEEL AND TIRE REMOVAL/INSTALLATION .)
  6. Remove the capsule cover. (See CAPSULE COVER REMOVAL/INSTALLATION [H3T] .)
  7. Remove the cowl grille cover assembly. (See COWL GRILLE REMOVAL/INSTALLATION .)
  8. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION .)
  9. Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION (L.H.D.) ).
  10. Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION .)
  11. Remove the side cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION .)
  12. Remove the cowl grille bracket. (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  13. Remove the windshield wiper motor and link. (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION .)
  14. Remove the strut tower bar. (See DRIVER-SIDE STRUT TOWER BAR REMOVAL/INSTALLATION .) (See PASSENGER-SIDE STRUT TOWER BAR REMOVAL/INSTALLATION .)
  15. Remove the engine compartment insulator (upper). (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  16. Remove the air cleaner component. (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  17. Remove the front under cover No. 2. (See REMOVE FRONT UNDER COVER NO. 2 .)
  18. Remove the front under cover No. 1. (See REMOVE FRONT UNDER COVER NO. 1 .)
  19. Remove the front under cover No. 3. (See REMOVE FRONT UNDER COVER NO. 3 .)
  20. Remove the floor under cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION .)
  21. Perform the high voltage handling. (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  22. Disconnect the ground plate. (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  23. Partially peel back the front over fender. (See FRONT OVER FENDER REMOVAL/INSTALLATION .)
  24. Remove the front mudguard. (See FRONT MUDGUARD REMOVAL/INSTALLATION .)
  25. Remove the front deflector. (See FRONT DEFLECTOR REMOVAL/INSTALLATION .)
  26. Remove the front splash shield. (See FRONT SPLASH SHIELD REMOVAL/INSTALLATION .)
  27. Remove the edge rubber. (See FRONT FENDER PANEL REMOVAL/INSTALLATION .)
  28. Remove the latch cover. (See FRONT BUMPER REMOVAL/INSTALLATION .)
  29. Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION .)
  30. Remove the center seal plate. (See ACTIVE AIR SHUTTER REMOVAL/INSTALLATION .)
  31. Remove the bracket (bumper upper side). (See ACTIVE AIR SHUTTER REMOVAL/INSTALLATION .)
  32. Remove the intake air guide (upper). (See ACTIVE AIR SHUTTER REMOVAL/INSTALLATION .)
  33. Remove the seal plate. (See ACTIVE AIR SHUTTER REMOVAL/INSTALLATION .)
  34. Remove the radiator mount bracket. (See RADIATOR REMOVAL/INSTALLATION [H3T] .)
  35. Remove the member bracket. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [AWD] .)
  36. Lower the engine 50 mm {2.0 in}. (See ENGINE MOUNT REMOVAL/INSTALLATION [H3T] .)
  37. Remove the PCM. (See PCM REMOVAL/INSTALLATION [H3T] .)
  38. Remove the turbocharger air outlet pipe No. 1 component. (See CYLINDER HEAD COVER REMOVAL/INSTALLATION [H3T] .)
  39. Remove the turbocharger air outlet pipe No. 2 component. (See KNOCK SENSOR (KS) REMOVAL/INSTALLATION [H3T] .)
  40. Remove the water-cooled charge air cooler reserve tank. (See WATER-COOLED CHARGE AIR COOLER RESERVE TANK REMOVAL/INSTALLATION [H3T] .)
  41. Remove the EGR valve. (See EGR VALVE REMOVAL/INSTALLATION [H3T] .)
  42. Remove the EGR cooler. (See EGR COOLER REMOVAL/INSTALLATION [H3T] .)
  43. Remove the intake manifold. (See INTAKE MANIFOLD REMOVAL/INSTALLATION [H3T] ).
  44. Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [H3T] )
  45. Remove the A/C compressor with the cooler hose still connected and secure it using wire or rope so that it is out of the way. (See A/C COMPRESSOR REMOVAL/INSTALLATION [H3T] .)
  46. Remove in the order indicated in the table.
    Fig 1: Water-Cooled Charge Air Cooler Components Location With Torque Specifications
    G16702186Courtesy of MAZDA MOTORS CORP.
    TIGHTENING TORQUE SPECIFICATIONS

    Step Part name
    1 Water hose
    (See WATER HOSE INSTALLATION NOTE )    		 - -
    2 Water hose
    (See WATER HOSE INSTALLATION NOTE  )    		 - -
    3 Cap - -
    4 Nut - 11 N.m {110 kgf.cm, 95 in.lbf}
    5 Wiring harness clip - -
    6 Terminal B cable - -
    7 Bolt - 9.5 N.m {97 kgf.cm, 84 in.lbf}
    8 Bracket - -
    9 Bolt
    (See BOLT REMOVAL NOTE )    		 - 9.5 N.m {97 kgf.cm, 84 in.lbf}
    10 Bolt - 18 N.m {1.85 kgf.m, 13.3 ft.lbf}
    11 Bracket
    (See BRACKET REMOVAL NOTE )    		 - -
    12 Water-cooled charge air cooler component - -
    13 Bolt - 9.5 N.m {97 kgf.cm, 84 in.lbf}
    14 Bracket - -
    15 Water-cooled charge air cooler air outlet pipe - -
    16 O-ring Replacement part -
    17 Bolt - 9.5 N.m {97 kgf.cm, 84 in.lbf}
    18 Water hose
    (See WATER HOSE INSTALLATION NOTE )    		 - -
    19 Water-cooled charge air cooler - -
  47. Install in the reverse order of removal.
  48. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [H3T] .)
  49. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [H3T] .)
  50. Refill the water-cooled charge air cooler coolant. (See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT [H3T] .)
  51. Perform air bleeding of engine coolant. (See ENGINE COOLANT REPLACEMENT [H3T] .)
  52. Perform air bleeding of water-cooled charge air cooler coolant. (See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT [H3T] .)
  53. Inspect for engine coolant leakage. (See ENGINE COOLANT REPLACEMENT [H3T] .)
  54. Inspect for water-cooled charge air cooler coolant leakage. (See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT [H3T] .)
  55. Perform the 360° view monitor system aiming. (See 360° VIEW MONITOR SYSTEM AIMING .)
  56. Perform the radar sensor (front) aiming. (See FRONT RADAR SENSOR AIMING .)
  57. Perform the radar sensor (front side) aiming. (See FRONT SIDE RADAR SENSOR AIMING .)
  58. Perform the radar sensor (rear side) aiming. (See REAR SIDE RADAR SENSOR AIMING .)
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