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Thread: Radiator replacement - detailed with photos

  1. #1
    Registered Member

    2002 Mazda Protege5

    Join Date
    Mar 2011
    Location
    New york
    Posts
    12

    Radiator replacement - detailed with photos

    I searched everywhere and other sites and could not find a detailed thread so I decided to create one to aid anyone wanting/having to do this.

    Remember to disconnect the battery and drain the system from the coolant. Now would be a good time to flush the system if it hasn't been done and maybe replace the thermostat

    New unit from ebay 78.00 http://cgi.ebay.com/ws/eBayISAPI.dll...=1058173368003





    Remove air intake note photos for instructions



    Loosen upper hose, reseviour hose and bracket nuts


    Remove fans. Note bolt locations. The top bolts are the only ones. Once removed they slide out upwards




    Unplug fans and unclip wire harness from fan base otherwise the fans won't slide out


    Push upper hose backwards or remove completely to be able to slide driver side fan upwards. Once fans are out disconnect lower hose and the at hoses




    Once the hoses are disconnected slide the radiator upwards to remove

    Don't forget to swap the rubber support mounts from the old radiator to the new one





    Insert the new radiator in carefully not to kink the panel

    Re install everything in the reverse order







    Fill the system with new coolant and make sure you get the air out of the system. There are threads on how to do this.

    Note:

    The old cap did not work so I had to get a short cap.
    Last edited by vicvega; 02-28-2015 at 02:37 AM. Reason: update
    Vic Vega
    2002 P5

  2. #2
    Registered Member

    02 Protege LX, 03 P5 (x2), 09 Miata, 07 Mazda3, 13 Fit, 09 Ody

    Join Date
    Aug 2013
    Location
    MD
    Posts
    110
    Just did this today. Pretty good write-up.

    Some things to note...
    1) get some hose clips in case you can't re-use the ones you have.
    2) when putting your hose clips back on 'seat' them in the indentations of your hose. This will keep it tighter.
    3) Those smaller hoses on the bottom are for ATF. So, they probably are not there if you have a manual. You will lose a little bit of ATF when taking these off so check your ATF afterwards because you may have to add a little bit. YMMV but I didn't have to add any.
    4) Do yourself a favor and check your front lower engine mount before starting this project. If it needs to be replaced it will be easier to replace when the radiator is out.
    13 Fit | 09 Ody | 09 Miata | 07 Mazda 3 | 03 Protege5 | 02 Protege

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