Mazda 323/626/929/GLC/MX-6/RX-7 1978-1989

Freeze Plugs

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REMOVAL AND INSTALLATION



See Figures 1 and 2

  1. Raise and safely support the vehicle, as required.
  2.  
  3. Drain the cooling system. Depending on the freeze plug's location, it may also be advisable to remove the drain plug from the side of the block; this will permit more thorough drainage of the coolant.
  4.  
  5. Drill a 1 / 2 in. (13mm) hole in the center of the freeze plug, then remove it with a slide hammer or prybar. Be careful to stop drilling as soon as the bit breaks through the plug to prevent damaging the engine.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: The freeze plug can be loosened using a hammer and punch



Click image to see an enlarged view

Fig. Fig. 2: Once the freeze plug has been loosened, it can be removed from the block

If drilling is not practical, you may instead remove the plug with a hammer and punch.

  1. Clean all dirt and corrosion from the freeze plug bore. Check the freeze plug bore for damage that would interfere with sealing. If the bore is damaged, it will have to be machined for an oversize plug.
  2.  

To install:
  1. Coat the plug bore and the freeze plug sealing surface with waterproof sealer.
  2.  
  3. Install cup-type freeze plugs with the flanged edge outward. The plug must be driven in with a tool that does not contact the flange of the plug. If an improper tool is used, the plug sealing edge will be damaged and leakage will result.
  4.  
  5. Expansion-type freeze plugs are installed with the flanged edge inward. The plug must be driven in with a tool that does not contact the crowned portion of the plug. If an improper tool is used, the plug and/or plug bore will be damaged.
  6.  
  7. Replace any drain plugs that were removed and lower the vehicle.
  8.  
  9. Fill the cooling system to the proper level, then start the engine and check for leaks.
  10.  

 
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