Mazda 2 Operating and installation instructions

Central
Service
Department
Service Information
Bermaz Motor Trading Sdn Bhd (9529-K)
No 7, Jalan Pelukis U1/46, Temasya Industrial Park, Seksyen U1, 40150 Shah Alam, Selangor Darul Ehsan, Malaysia
Tel : [phone] Fax : [phone]
Website: www.mazda.com.my
Category
HEATER AND AIR
CONDITIONER SYSTEM
SI Type REPAIR GUIDANCE
Ref. No.
BR72/19
Page
1 of 10
Distribute to:-
Director Divisional/GM Branches Dealers PDI CPD
Warranty Training Dealer Development Sales / Marketing CRM
Date Issued / Revised
JANUARY 21, 2020
Applicable Model
Subject
Mazda2 (DJ/DL), Mazda3 (BM/BP),
Mazda6 (GJ/GL), CX-3 (DK), CX-5
(KE/KF), CX-9 (TC) and MX-5 (ND)
INSUFFICIENT HEATER PERFORMANCE
1. DESCRIPTION
Some customers may complain about an insufficient heater performance even after the engine reaching
normal operating temperature.
2. CAUSE
Crystallized foreign substances may be generated causing clogging of the heater core and a shortage of the
engine coolant circulation.
3. MASS PRODUCTION CHANGE
Composition of the coolant has been changed.
4. SUBJECT VIN and PRODUCTION DATE RANGE
Model
Subject VIN
Production Date Range
From
To
Mazda2
(DJ/DL)
MM6 DJ**** **
100001
445165
From October 8, 2014 to March 21, 2019
MM6 DL**** **
Mazda3 (BM)
JM6 BM**** **
100001
351420
ALL
PP1 BMA171 *M
TBD
TBD
PP1 BMA271 *M
TBD
TBD
PP1 BMB271 *M
TBD
TBD
Mazda3 (BP)
JM6 BP**** **
100001
100066
From March 19, 2019 to April 1, 2019
Mazda6 (GJ)
JM6 GJ**** **
100001
243006
All
Mazda6 (GL)
JM6 GL**** **
100001
322730
From July 11, 2016 to March 25, 2019
CX-3 (DK)
JM6 DK**** **
111045
420456
From September 15, 2015 to April 1, 2019
CX-5 (KE)
JM6 KE**** **
101920
425644
ALL
CX-5 (KF)
PP1 KFA171 **
TBD
TBD
PP1 KFA271 **
TBD
TBD
PP1 KFA231 **
TBD
TBD
PP1 KFA221 **
TBD
TBD
PP1 KFB221 **
TBD
TBD
CX-9 (TC)
JM6 TC**** **
200001
319665
From April 1, 2017 to April 1, 2019
MX-5 (ND)
JM6 ND**** **
100001
300084
From May 22, 2015 to March 21, 2019

Bermaz Technical Service Information BR072/19
Page 2of 10
Bermaz Motor Trading Sdn Bhd (9529-K)
No 7, Jalan Pelukis U1/46, Temasya Industrial Park, Seksyen U1, 40150 Shah Alam, Selangor Darul Ehsan, Malaysia
Tel : [phone] Fax : [phone]
Website: www.mazda.com.my
5. PART INFORMATION
Part Number
Description
Qty.
Remark
(Refer to EPC)
Hose Clip
2
Replacement part
Obtain the part number on EPC, Section 6100*.
TBD
Coolant (4 x 5L)
1
As required for refilling
Example: 7.3L (KE SKYACTIV-G 2.0)/9.1L (KE
SKYACTIV-D 2.2)
4.0L for flushing
NOTE: For coolant, either use one of the part number and claim applicable amount as described in
“Warranty Information”.
When replacing the heater core
NOTE: Check the parts catalogue for correct part numbers applicable to VIN.
EPC Section
Part Number
Part Name
Qty.
Note
6110*
Front Heater Unit
Components
****-61-A10*
Heater Unit Core
1
-
****-61-J17*
or
****-76-754*
O-ring,
Expansion Valve-Low
1
-
****-61-J17*
or
****-61-J19*
O-ring,
Expansion Valve-High
1
-
6130*
Front Air Conditioner
****-61-J17*
O-ring,
Cooling Pipe-Low
1
-
****-61-17*
or
****-61-19*
O-ring,
Cooling Pipe-High
1
-
6100* Front Heater
or
1500* Cooling System
****-61-242*
or
****-15-182*
Clip, Heater Hose
0 or 2
Check if it is “R” part on
Workshop Manual.
6820*
Pillar Trims
****-68-162*
Clip. Trim
0 or 2
-
6170*
Rear Air Conditioning
Cooling Unit
****-61-D10*
Heater Unit Core, Rear
1
For Vehicles, Rear Heater
equipped.
****-61-J17*
O-ring,
Expansion Valve, Low
2
****-61-J17*
O-ring,
Expansion Valve, High
2
3200*
Steering Wheel
****-11-003*
or
****-11-007*
or
****-81-200*
Bolt,
Steering Wheel
1
-
3210*
Steering Column &
Shafts
****-32-099*
Bolt,
Lower-Intermediate Shaft
1
-
****-32-099*
Bolt,
Upper-Intermediate Shaft
1
-
5560*
Dashboard & Related
Parts
9YA0-20-682
Bolt,
Dashboard
1 or 2
Not necessary for MX-5.
NOTE:Composition of FL22 coolant has been changed. Ask your retailer how to obtain the new coolant.

Bermaz Technical Service Information BR072/19
Page 3of 10
Bermaz Motor Trading Sdn Bhd (9529-K)
No 7, Jalan Pelukis U1/46, Temasya Industrial Park, Seksyen U1, 40150 Shah Alam, Selangor Darul Ehsan, Malaysia
Tel : [phone] Fax : [phone]
Website: www.mazda.com.my
Replacement Parts Location: (Figures are for CX-5 (KE))
BOLT, STEERING WHEEL
BOLT, UPPER-INTERMEDIATE SHAFT
BOLT, LOWER-INTERMEDIATE SHAFT
BOLT, DASHBOARD
CLIP, TRIM
O-RING, EXPANSION VALVE-LOW
O-RING, EXPANSION VALVE-HIGH
O-RING, COOLER PIPE-HIGH
O-RING, COOLER PIPE-LOW
CLIP, HEATER HOSE

Bermaz Technical Service Information BR072/19
Page 4of 10
Bermaz Motor Trading Sdn Bhd (9529-K)
No 7, Jalan Pelukis U1/46, Temasya Industrial Park, Seksyen U1, 40150 Shah Alam, Selangor Darul Ehsan, Malaysia
Tel : [phone] Fax : [phone]
Website: www.mazda.com.my
6. WARRANTY INFORMATION
HEATER CORE FLUSHING only
Symptom Code
59 (Insufficient heating)
Damage Code
93 (Clogged)
Causal Part No.
****-61-A10
Use part number of the heater core applicable to the VIN according to EPC.
Quantity
0
Operation No.
Labor Hours
Operation No.
Labor Hours
Remark
XXRA3XRX
1.3 Hrs.
-
Period Covered
Normal Warranty Period
NOTE:
•Claim the hose clip and coolant as Related Part.
•Claim the actual expense of local purchases such as pump, hose etc. using the sublet code “Z9”
(Others). (FOR FIRST TIME REPAIR ONLY)
HEATER CORE REPLACEMENT & FLUSHING
Symptom Code
59 (Insufficient heating)
Damage Code
93 (Clogged)
Causal Part No.
**** 61 A10*
Use part number of the heater core applicable to the VIN according to EPC.
Qty.
1
Operation No. and
Hours
XXN7TXRX
Model
Without i-stop
With i-stop
MAZDA2 (DJ/DL)
4.8 Hrs.
4.9 Hrs.
MAZDA3 (BM/BN)
4.7 Hrs.
4.8 Hrs.
MAZDA3 (BP)
4.8 Hrs.
4.9 Hrs.
MAZDA6 (GJ/GL)
4.7 Hrs.
4.8 Hrs.
CX-3 (DK)
4.8 Hrs.
4.9 Hrs.
CX-5 (KE/KF)
4.8 Hrs.
4.9 Hrs.
CX-9 (TC) 2WD
6.8 Hrs.
6.8 Hrs.
CX-9 (TC) 4WD
7.3 Hrs.
7.3 Hrs.
MX-5 (ND)
4.3 Hrs.
4.4 Hrs.
Operation: Perform the diagnosis procedure, replace the heater core and
replace engine coolant twice.
Period Covered
Normal Warranty Period
NOTE:
Enter coolant, refrigerant and all replacement parts in Related Part.
7. REPAIR PROCEDURE
If you receive a customer complaint on this concern, diagnose by comparing the two temperatures of the
heater hose IN and OUT to the heater core.
If there is difference in the temperatures, flush the heater core to remove out the foreign substances using
the procedure “HEATER CORE FLUSHING PROCEDURE”.
If Circulation Pump is not available in the market, replace the heater core with a new one. In addition,
replace the deteriorated engine coolant twice using the procedure “HEATER CORE REPLACING
PROCEDURE”.
NOTE:
Since all of the deteriorated old coolant cannot be drained out by one time, do the coolant replacement
twice.

Bermaz Technical Service Information BR072/19
Page 5of 10
Bermaz Motor Trading Sdn Bhd (9529-K)
No 7, Jalan Pelukis U1/46, Temasya Industrial Park, Seksyen U1, 40150 Shah Alam, Selangor Darul Ehsan, Malaysia
Tel : [phone] Fax : [phone]
Website: www.mazda.com.my
①
<HEATER CORE FLUSHING PROCEDURE>
-Things to prepare locally-
No.
Name
Note
1
Circulation Pump (1)
Power Output: min. 720l/hr./Pump Head approx. 2m
(e.g. Eheim compact+ 2000 or Eden 135)
2
Water Hose (2)
Length: 2.5m - 3m
Inner diameter: 18mm
3
Hose Band (1)
Used to secure water hose (2) to the circulation pump (1).
4
Citric Acid (2 x 15
grams)
Pure citric acid as powder is available in grocery or drug stores.
Note: Usage of acetic acid or other acids may cause damage to the heater core.
5
Bucket (2)
Capacity: 10 liters
1. Drain the engine coolant. (See Workshop Manual: ENGINE COOLANT REPLACEMENT)
2. Disconnect the battery. (See Workshop Manual: BATTERY REMOVAL/INSTALLATION)
3. Remove the heater hoses (IN and OUT) from the heater core pipes.
NOTE:
The heater unit INLET pipe is always on upper side and the OUTLET pipe is on lower side.
4. Connect two water hoses (inlet (2) and outlet (3)) to the pipes of the heater core and secure them
using the original hose bands (1).
(2) Water Inlet
(1) Water Outlet
1
2
3

Bermaz Technical Service Information BR072/19
Page 6of 10
Bermaz Motor Trading Sdn Bhd (9529-K)
No 7, Jalan Pelukis U1/46, Temasya Industrial Park, Seksyen U1, 40150 Shah Alam, Selangor Darul Ehsan, Malaysia
Tel : [phone] Fax : [phone]
Website: www.mazda.com.my
5. Connect the open end of the hose (which is connected to the heater core OUTLET) to the circulation
pump (PUMP) and secure it with a hose band.
FLUSH HEATER CORE WITH WATER.
6. Fill bucket (A) with clean water and immerse the PUMP (1) into the bucket.
7. Place the end of hose (2) (connected to the heater core INLET pipe) in the empty bucket (B).
8. Turn on the PUMP and flush the heater core for about 1 minute.
After the flushing, dispose the water collected in bucket (B).
WASH HEATER CORE BY CIRCULATING DETERGENT (TWO TIMES).
9. Fill bucket (A) with 4 liters of warm water (max. 40°C), add 15 grams of citric acid powder and stir it well.
10. Place the PUMP and the open end of the other hose into bucket (A).
11. Turn on the PUMP and allow the mixture to circulate through the heater core for about 1 hr.
12. Dispose the used mixture.
13. Repeat step 9 to 12 for another cycle of 1 hr. using a fresh mixture of water and citric acid.
E.g.1 using EDEN product pump
E.g.2 using EHEIM product pump

Bermaz Technical Service Information BR072/19
Page 7of 10
Bermaz Motor Trading Sdn Bhd (9529-K)
No 7, Jalan Pelukis U1/46, Temasya Industrial Park, Seksyen U1, 40150 Shah Alam, Selangor Darul Ehsan, Malaysia
Tel : [phone] Fax : [phone]
Website: www.mazda.com.my
RINSE HEATER CORE BY CIRCULATING WATER.
14. Place a hose (3) of your local fresh water supply into bucket (B).
15. Place the PUMP connected with the hose (OUT) (1) also in the bucket (B).
16. Place the hose (IN) (2) to a local drain.
17. Open the tap to run water.
Turn on the PUMP and circulate water through the heater core for 15 minutes.

Bermaz Technical Service Information BR072/19
Page 8of 10
Bermaz Motor Trading Sdn Bhd (9529-K)
No 7, Jalan Pelukis U1/46, Temasya Industrial Park, Seksyen U1, 40150 Shah Alam, Selangor Darul Ehsan, Malaysia
Tel : [phone] Fax : [phone]
Website: www.mazda.com.my
CIRCULATE ENGINE COOLANT THROUGH HEATER CORE TO REMOVE REMAINING WATER.
18. Fill the bucket (A) with 4 liters of engine coolant and place the PUMP (1) in it.
19. Place the hose (IN) (2) in the empty bucket (B).
20. Turn on the PUMP and run the engine coolant through the heater core to remove the remaining fresh water.
Continue it until all 4 liters are used up.
21. Remove the two water hoses from the heater core.
22. Install the heater hoses (IN and OUT) to the heater core with new hose band.
23. Reconnect the battery. (See Workshop Manual: BATTERY REMOVAL/INSTALLATION)
24. Refill the cooling system with FL22 (55% premix) coolant at the radiator filler neck until it is
close to the top of the filler neck.
NOTE:
•Do not use water to adjust the coolant concentration.
•Minerals contained in the water may generate deposits causing clogging of the cooling
system and rust on the parts.
•Service coolant (FL22 55% pre-diluted) using a specified quality of water is the solution.
25. Install the radiator cap.
NOTE:
•Since all of the deteriorated old coolant cannot be drained out by one time, do the coolant
replacement twice.
WARNING:
•Never remove cooling system cap or loosen the radiator drain plug while the engine is running, or
when the engine and radiator are hot.
Scalding engine coolant and steam may shoot out cause serious injury.
It may also damage the engine and cooling system.
•Turn off the engine and wait until it is cool.
Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop.
Step back while the pressure escapes.
•When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove
it.
26. Start the engine and warm-up to normal operating temperature to open the thermostat.
To confirm that thermostat is fully open, touch the lower radiator hose.
CAUTION:

Bermaz Technical Service Information BR072/19
Page 9of 10
Bermaz Motor Trading Sdn Bhd (9529-K)
No 7, Jalan Pelukis U1/46, Temasya Industrial Park, Seksyen U1, 40150 Shah Alam, Selangor Darul Ehsan, Malaysia
Tel : [phone] Fax : [phone]
Website: www.mazda.com.my
•The lower radiator hose is getting hot when the thermostat is opened.
•Use a thick cloth or gloves when touching the hose.
Refer to the Workshop Manual “THERMOSTAT INSPECTION” for thermostat opening temperatures.
27. Mix the coolant in the cooling system using the following steps:
NOTE:
•Below A) B) are sample from a certain CX-5 (KE).
•Refer to the Workshop Manual “ENGINE COOLANT REPLACEMENT”.
A) Run the engine at 2,500 rpm for 5 min.
B) Maintain the engine speed at 3,000 rpm for 5 seconds, then allow the engine to idle.
28. Drain the coolant and repeat the step 24-27 to replace the coolant at the second time.
29. Allow the engine to cool down.
30. Replace the coolant in the reservoir tank with new FL22.
31. Inspect the engine coolant and reservoir tank levels and adjust with new FL22 as needed.
32. Verify repair that the heater system performs sufficiently.
<HEATER CORE REPLACING PROCEDURE>
Perform only when a Circulation Pump is NOT available in the market.
NOTE:
•Since all of the deteriorated old coolant cannot be drained out by one time, do the coolant replacement twice.
WARNING:
•Never remove the cooling system cap or loosen the radiator drain plug while the engine is running, or
when the engine and radiator are hot.
Scalding engine coolant and steam may shoot out cause serious injury.
It may also damage the engine and cooling system.
•Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop.
Step back while the pressure escapes.
•When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.
1. Replace the heater core with a new one according to the procedure in the workshop manual “A/C
UNIT REMOVAL/INSTALLATION” and “A/C UNIT DISASSEMBLY/ASSEMBLY”.
2. Make sure the radiator cap is removed, then drain the coolant from the radiator drain plug as much as
possible.
3. Tighten the radiator drain plug.
4. Refill the cooling system with FL22 (55% premix) coolant at the radiator filler neck until it is close to
the top of the filler neck.
NOTE:
•Do not use water to adjust the coolant concentration.
•Minerals contained in the water may generate deposits causing clogging of the cooling
system and rust on the parts.
•Service coolant (FL22 55% pre-diluted) using a specified quality of water is the solution.
5. Install the radiator cap.

Bermaz Technical Service Information BR072/19
Page 10 of 10
Bermaz Motor Trading Sdn Bhd (9529-K)
No 7, Jalan Pelukis U1/46, Temasya Industrial Park, Seksyen U1, 40150 Shah Alam, Selangor Darul Ehsan, Malaysia
Tel : [phone] Fax : [phone]
Website: www.mazda.com.my
6. Start the engine and warm-up to normal operating temperature to open the thermostat.
To confirm that thermostat is fully open, touch the lower radiator hose.
CAUTION:
•The lower radiator hose is getting hot when the thermostat is opened.
•Use a thick cloth or gloves when touching the hose.
Refer to the Workshop Manual “THERMOSTAT INSPECTION” for thermostat opening temperatures.
7. Mix the coolant in the cooling system using the following steps:
NOTE:
•Below A) B) are sample for CX-5 (KE).
•For other models, refer to the Workshop Manual “ENGINE COOLANT REPLACEMENT”.
A) Run the engine at 2,500 rpm for 5 min.
B) Maintain the engine speed at 3,000 rpm for 5 seconds, then allow the engine to idle.
8. Drain the coolant and repeat the step 2 –7 to replace the coolant at the second time.
9. Allow the engine to cool down.
10. Replace the coolant in the reservoir tank with new FL22.
11. Inspect the engine coolant and reservoir tank levels and adjust with new FL22 as needed.
Prepared by
Verified by
Approved by
Name: Yap Soon Loong
Name: Brad Soy
Chee Chien
Name: Lim Sai Woh
Name: Chai Kok Heong
Designation: Assistant
Manager - Technical
Designation: Manager -
Technical
Designation: Senior
Manager - Technical
Designation: Senior Manager
-CSD & Branches