Mazda Car 2002-04

Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Remove the air cleaner.
  8.  
  9. Remove the shroud panel.
  10.  
  11. Remove the cooling fan.
  12.  
  13. Disconnect the upper radiator hose from the radiator, on the 2.3L engine.
  14.  
  15. Disconnect the oil hose from the radiator if equipped with an automatic transaxle.
  16.  
  17. Remove the engine coolant reserve hose on the 3.0L engine.
  18.  
  19. Remove the radiator hoses, radiator bolts and the radiator.
  20.  

To install:

  1. Install the components in the reverse of removal. Tighten the radiator bolts to 45-61 inch lbs.
  2.  
  3. Fill the cooling system and check for leaks.
  4.  
  5. Check the transaxle fluid level.
  6.  

  1. Disconnect the negative battery cable.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Remove the fresh-air duct.
  6.  
  7. Remove the transaxle oil pipes on 2.0L (FS) engines with an automatic transaxle.
  8.  
  9. Disconnect the coolant reservoir hose from the radiator.
  10.  
  11. Unplug the fan control module connector.
  12.  
  13. Disconnect the radiator hoses.
  14.  
  15. Remove the radiator mounts and remove the radiator and fan assembly.
  16.  

To install:

  1. Install the components in the reverse of removal.
  2.  
  3. Fill the cooling system and check for leaks.
  4.  
  5. Check the transaxle fluid level.

    Click image to see an enlarged view

    Fig. Exploded view of the radiator assembly-626 2.0L (FS) engine



    Click image to see an enlarged view

    Fig. Exploded view of the radiator assembly-626 2.5L (KL) engine

  6.  

  1. Disconnect the negative battery cable.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Remove the air hose
  6.  
  7. Disconnect the upper radiator hose.
  8.  
  9. Remove the cooling fan motor connector and condenser fan motor connector
  10.  
  11. Disconnect the upper radiator hose.
  12.  
  13. Remove the cooling and condenser fans.
  14.  
  15. If equipped with a manual transaxle, disconnect the transmission cooler lines from the radiator.
  16.  
  17. Unfasten the radiator mounts and remove the radiator.
  18.  

To install:

  1. Install the components in the reverse of removal.
  2.  
  3. Fill the cooling system and check for leaks.
  4.  
  5. Check the transaxle fluid level.

    Click image to see an enlarged view

    Fig. Exploded view of the radiator assembly-Miata

  6.  


CAUTION
Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

  1. Remove the battery cover.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the under cover.
  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Disconnect the coolant reservoir hose from the radiator.
  10.  
  11. Position the front wiring harnesses out of the way.
  12.  
  13. Remove the fan control module connector.
  14.  
  15. Unlock the cooling fan component lower side tabs a at two points by pressing the cooling fan side tabs, remove upper side tabs, then remove the cooling fan component from the radiator
  16.  
  17. Disconnect the radiator hoses.
  18.  
  19. Remove the radiator mount.
  20.  
  21. Remove the radiator as follows:
    1. Remove the condenser from the radiator with the pipes still connected, by pressing the radiator side tabs to unlock tabs b on the condenser.
    2.  
    3. Remove rubber mount A from the mount installation hole.
    4.  
    5. Tilt the radiator to the engine side.
    6.  
    7. Remove rubber mount B from the mount installation hole.
    8.  
    9. Remove the radiator from the bottom of the vehicle.
    10.  

  22.  

To install:

  1. Install the radiator, mount and hoses.
  2.  
  3. Install the condenser to the radiator by aligning lower side tabs with the radiator side tabs, install upper tabs b, then install lower side tabs.
  4.  
  5. Insert the cooling fan component tabs to the radiator to install the cooling fan component.
  6.  
  7. Install the remaining components in the reverse of removal.
  8.  
  9. Fill the cooling system and check for leaks.
  10.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Remove the air cleaner.
  8.  
  9. Remove the shroud panel.
  10.  
  11. Remove the cooling fan.
  12.  
  13. Disconnect the upper radiator hose from the radiator, on the 2.3L engine.
  14.  
  15. Disconnect the oil hose from the radiator if equipped with an automatic transaxle.
  16.  
  17. Remove the engine coolant reserve hose on the 3.0L engine.
  18.  
  19. Remove the radiator hoses, radiator bolts and the radiator.
  20.  

To install:

  1. Install the components in the reverse of removal. Tighten the radiator bolts to 45-61 inch lbs.
  2.  
  3. Fill the cooling system and check for leaks.
  4.  
  5. Check the transaxle fluid level.
  6.  

1.5L, 1.6L 1.8L And 2.0L Engines



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air hose
     
    Upper radiator hose
     
    Cooling and condenser fan electrical connectors
     
    Lower radiator hose
     
    Cooling fan
     
    Condenser fan
     
    Oil cooler lines, if equipped
     
    Radiator
     

  6.  

To install:

  1. Install or connect the following:

    Radiator and torque the mounting bolts to 18 ft. lbs. (25 Nm)
     
    Oil cooler lines, if equipped
     
    Cooling and condenser fans and torque the bolts to 89 inch lbs. (10 Nm)
     
    Lower radiator hose
     
    Fan electrical connectors
     
    Upper radiator hose
     
    Air hose
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system to the proper level.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

2.3L (Kj) Engine



  1. Disconnect the negative battery cable.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Remove the charge air cooler.
  6.  
  7. Remove the upper seal board.
  8.  
  9. Disconnect the coolant reservoir hose from the radiator and remove the reservoir.
  10.  
  11. Unplug the fan connector.
  12.  
  13. Remove the cooling fan bolts and fan assemblies.
  14.  
  15. Remove the transaxle oil pipes.
  16.  
  17. Disconnect the radiator hoses.
  18.  
  19. Remove the radiator mounts and remove the radiator assembly.
  20.  

To install:

  1. Install the components in the reverse of removal.
  2.  
  3. Fill the cooling system and check for leaks.
  4.  
  5. Check the transaxle fluid level.

    Click image to see an enlarged view

    Fig. Exploded view of the radiator assembly-Millenia with 2.3 L engine

  6.  

2.3L Engines



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right side splash shield
     
    Radiator grill
     
    Upper seal board
     
    Coolant reservoir tank
     
    Fan motor electrical connectors
     
    Cooling fan
     
    Condenser fan
     
    Upper and lower radiator hoses
     
    Oil cooler lines
     
    Radiator bracket
     
    Radiator
     

  6.  

To install:

  1. Install or connect the following:

    Radiator and bracket. Torque the bracket bolts to 89 inch lbs. (10 Nm)
     
    Oil cooler lines
     
    Upper and lower radiator hoses
     
    Condenser fan and torque the bolts to 89 inch lbs. (10 Nm)
     
    Cooling fan and torque the bolts to 89 inch lbs. (10 Nm)
     
    Fan motor electrical connectors
     
    Coolant reservoir tank and torque the bolt to 89 inch lbs. (10 Nm)
     
    Upper seal board
     
    Radiator grill
     
    Right side splash shield
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system to the proper level.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

2.5L (Kl) Engine



  1. Disconnect the negative battery cable.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Remove the right side slash shield.
  6.  
  7. Remove the radiator grille.
  8.  
  9. Remove the upper seal board.
  10.  
  11. Disconnect the coolant reservoir hose from the radiator and remove the reservoir.
  12.  
  13. Unplug the fan connector.
  14.  
  15. Remove the cooling fan bolts and fan assemblies.
  16.  
  17. Remove the transaxle oil pipes.
  18.  
  19. Disconnect the radiator hoses.
  20.  
  21. Remove the radiator mounts and remove the radiator assembly.
  22.  

To install:

  1. Install the components in the reverse of removal.
  2.  
  3. Fill the cooling system and check for leaks.
  4.  
  5. Check the transaxle fluid level.

    Click image to see an enlarged view

    Fig. Exploded view of the radiator assembly-Millenia with 2.5 L engine

  6.  

2.5L Engine



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Charge air cooler
     
    Upper seal board
     
    Coolant reservoir tank
     
    Fan motor electrical connectors
     
    Cooling fan
     
    Condenser fan
     
    Oil cooler lines
     
    Upper and lower radiator hoses
     
    Radiator bracket
     
    Radiator
     

  6.  

To install:

  1. Install or connect the following:

    Radiator and bracket. Torque the bolts to 89 inch lbs. (10 Nm)
     
    Upper and lower radiator hoses
     
    Oil cooler lines
     
    Cooling and condenser fans and torque the bolts to 89 inch lbs. (10 Nm)
     
    Fan motor electrical connectors
     
    Coolant reservoir tank and torque the bolt to 89 inch lbs. (10 Nm)
     
    Upper seal board
     
    Charge air cooler
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system to the proper level.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

With Turbocharger



  1. Disconnect the negative battery cable.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Remove the fresh-air duct.
  6.  
  7. Disconnect the electrical connectors.
  8.  
  9. Remove the air hose.
  10.  
  11. Unplug the fan control module connector.
  12.  
  13. Remove the fan assembly.
  14.  
  15. Disconnect the upper radiator hose.
  16.  
  17. Disconnect the lower radiator hose.
  18.  
  19. Remove the radiator mounts and remove the radiator and fan assembly.
  20.  

To install:

  1. Install the components in the reverse of removal.
  2.  
  3. Fill the cooling system and check for leaks.

    Click image to see an enlarged view

    Fig. Exploded view of the radiator assembly-Protégé, with a turbocharger

  4.  

Without Turbocharger



  1. Disconnect the negative battery cable.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Remove the fresh-air duct.
  6.  
  7. Disconnect the upper radiator hose.
  8.  
  9. Unplug the fan control module connector.
  10.  
  11. Disconnect the lower radiator hose.
  12.  
  13. Remove the fan assembly.
  14.  
  15. Remove the transaxle oil pipes models with an automatic transaxle.
  16.  
  17. Remove the radiator mounts and remove the radiator and fan assembly.
  18.  

To install:

  1. Install the components in the reverse of removal.
  2.  
  3. Fill the cooling system and check for leaks.
  4.  
  5. Check the transaxle fluid level.

    Click image to see an enlarged view

    Fig. Exploded view of the radiator assembly-Protégé, without a turbocharger

  6.  

 
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