Mazda Car 2002-04

Removal & Installation

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  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air hose.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Remove the thermostat housing bolts and the housing.
  8.  
  9. Remove the thermostat and gasket.
  10.  
  11. Clean the gasket mating surfaces.
  12.  

To install:

  1. Installation is the reverse of a removal. Always use a new gasket and verify that the jiggle pin is at the top.
  2.  
  3. Install a new gasket with the seal print side facing the cylinder head.
  4.  
  5. Tighten the housing to the specifications in the illustration.
  6.  
  7. Check and fill the cooling system.

    Click image to see an enlarged view

    Fig. Exploded view of the thermostat assembly-Miata



    Click image to see an enlarged view

    Fig. Verify that the jiggle pin is at the top-Miata



    Click image to see an enlarged view

    Fig. Install a new gasket with the seal print side facing the cylinder head-Miata

  8.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fresh air duct.
  4.  
  5. Remove the air cleaner on 1.6L engines.
  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Remove the lower radiator hose.
  10.  
  11. Remove the thermostat housing bolts and the housing.
  12.  
  13. Remove the thermostat and gasket.
  14.  
  15. Clean the gasket mating surfaces.
  16.  

To install:

  1. Installation is the reverse of a removal. Always use a new gasket and verify that the jiggle pin is aligned with the projection of the thermostat gasket as illustrated.
  2.  
  3. On 1.6L engines, install the thermostat into the thermostat case, with the jiggle pin at the top.
  4.  
  5. On 2.0L engines, install the thermostat into the thermostat case, aligning the jiggle pin and projection at the top as illustrated.
  6.  
  7. On 1.6L engines, install the thermostat into the thermostat case, aligning the projection on the gasket to the thermostat case as illustrated.
  8.  
  9. Tighten the housing to the specifications in the illustration.
  10.  
  11. Check and fill the cooling system.

    Click image to see an enlarged view

    Fig. Exploded view of the thermostat assembly-Protégé



    Click image to see an enlarged view

    Fig. Install the thermostat into the thermostat case, with the jiggle pin at the top-Protégé with the 1.6L (ZM) engine



    Click image to see an enlarged view

    Fig. Install the thermostat into the thermostat case, aligning the jiggle pin and projection at the top-Protégé with the 2.0L (FS) engine



    Click image to see an enlarged view

    Fig. Install a new gasket with the seal print side facing the cylinder head-Protégé with 1.6L engines

  12.  


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 and splash shield as a single unit.
  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Position the coolant reserve tank out of the way.
  10.  
  11. Remove the plug hole plate by lifting off and removing the plug hole plate from the areas shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Plug hole plate locations-Mazda 3 models

  12.  
  13. Position the drive belt out of the way.
  14.  
  15. Remove the drive belt tensioner.
  16.  
  17. Disconnect the water hose and lower radiator hose from the thermostat.
  18.  
  19. Remove the thermostat retainers, thermostat housing, thermostat and gasket.
  20.  

To install:

  1. Installation is the reverse of removal. Use a new thermostat housing gasket and tighten the thermostat housing retainers to 71-101 in. lbs. (8-11.5 Nm).
  2.  
  3. Fill the cooling system and check for leaks.
  4.  

2.0L (Fs) Engine



  1. Disconnect the negative battery cable.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Remove the lower radiator hose.
  6.  
  7. Remove the thermostat housing bolts and the housing.
  8.  
  9. Remove the thermostat and gasket.
  10.  
  11. Clean the gasket mating surfaces.
  12.  

To install:

  1. Installation is the reverse of a removal. Always use a new gasket and verify that the jiggle pin is aligned with the projection of the thermostat gasket as illustrated.
  2.  
  3. Install the thermostat into the thermostat case, aligning the projection on the gasket to the thermostat case as illustrated.
  4.  
  5. Tighten the housing to the specifications in the illustration.
  6.  
  7. Check and fill the cooling system.

    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Verify that the jiggle pin is aligned with the projection of the thermostat gasket as illustrated-626



    Click image to see an enlarged view

    Fig. Install the thermostat into the thermostat case, aligning the projection on the gasket to the thermostat case as illustrated-626

  8.  

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 duct
  6.  
  7. Remove the air cleaner.
  8.  
  9. Remove the resonator.
  10.  
  11. Remove the thermostat housing bolts and the housing.
  12.  
  13. Remove the thermostat and gasket.
  14.  
  15. Clean the gasket mating surfaces.
  16.  

To install:

  1. Installation is the reverse of a removal. Always use a new gasket and verify that the jiggle pin is aligned with the projection of the thermostat gasket as illustrated.
  2.  
  3. Tighten the housing to the specifications in the illustration.
  4.  
  5. Check and fill the cooling system.

    Click image to see an enlarged view

    Fig. Exploded view of the thermostat assembly-Millenia 2.3 (KJ engine



    Click image to see an enlarged view

    Fig.

  6.  

2.3L (L3) Engine



  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 drive belt.
  8.  
  9. Remove the power steering pump with hoses and pipe still connected. Position the P/S oil pump out of the way.
  10.  
  11. Disconnect the water hose and lower radiator hose from the thermostat.
  12.  
  13. Remove the thermostat retainers, thermostat housing, thermostat and gasket.
  14.  

To install:

  1. Installation is the reverse of removal. Use a new thermostat housing gasket and tighten the thermostat housing retainers to 71-101 in. lbs. (8-11.5 Nm).
  2.  
  3. Fill the cooling system and check for leaks.
  4.  

2.5L (Kl) Engine



  1. Disconnect the negative battery cable.
  2.  
  3. Remove the ignition coil.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Remove the water inlet pipe on models with a manual transaxle.
  8.  
  9. Remove the oil cooler if equipped with an automatic transaxle.
  10.  
  11. Remove the thermostat housing bolts and the housing.
  12.  
  13. Remove the thermostat and gasket.
  14.  
  15. Clean the gasket mating surfaces.
  16.  

To install:

  1. Installation is the reverse of a removal. Always use a new gasket and verify that the jiggle pin is aligned with the projection of the thermostat gasket as illustrated.
  2.  
  3. Install the thermostat into the thermostat case, aligning the projection on the gasket to the thermostat case as illustrated.
  4.  
  5. Tighten the housing to the specifications in the illustration.
  6.  
  7. Check and fill the cooling system.

    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Verify that the jiggle pin is aligned with the projection of the thermostat gasket as illustrated-626



    Click image to see an enlarged view

    Fig. Install the thermostat into the thermostat case, aligning the projection on the gasket to the thermostat case as illustrated-626

  8.  

  1. Disconnect the negative battery cable.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Remove the water inlet pipe.
  8.  
  9. Remove the engine harness bracket.
  10.  
  11. Remove the thermostat housing bolts and the housing.
  12.  
  13. Remove the thermostat and gasket.
  14.  
  15. Clean the gasket mating surfaces.
  16.  

To install:

  1. Installation is the reverse of a removal. Always use a new gasket and verify that the jiggle pin is aligned with the projection of the thermostat gasket as illustrated.
  2.  
  3. Install the thermostat into the thermostat case, aligning the projection on the gasket to the thermostat case as illustrated.
  4.  
  5. Tighten the housing to the specifications in the illustration.
  6.  
  7. Check and fill the cooling system.

    Click image to see an enlarged view

    Fig. Exploded view of the thermostat assembly-Millenia 2.5L (KL) engine



    Click image to see an enlarged view

    Fig.

  8.  

3.0L (Aj) Engine



  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 drive belt.
  8.  
  9. Disconnect upper and lower radiator hoses.
  10.  
  11. Remove the thermostat retainers, thermostat housing, thermostat and gasket.
  12.  

To install:

  1. Installation is the reverse of removal. Make sure to install the thermostat with the jiggle valve at the top. Use a new thermostat housing gasket and tighten the thermostat housing retainers to 71-101 in. lbs. (8-11.5 Nm).
  2.  
  3. Fill the cooling system and check for leaks.

    Click image to see an enlarged view

    Fig. Make sure to install the thermostat with the jiggle valve at the top-Mazda 6 with 3.0L engine

  4.  

Mazdaspeed6



  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 drive belt.
  8.  
  9. Remove the power steering pump with hoses and pipe still connected. Position the P/S oil pump out of the way.
  10.  
  11. Disconnect the water hose and lower radiator hose from the thermostat.
  12.  
  13. Remove the thermostat retainers, thermostat housing, thermostat and gasket.
  14.  

To install:

  1. Installation is the reverse of removal. Use a new thermostat housing gasket and tighten the thermostat housing retainers to 71-101 in. lbs. (8-11.5 Nm).
  2.  
  3. Fill the cooling system and check for leaks.
  4.  

 
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