1G Protege: Radiator Swap
 

This is my How-To on swaping a radiator in a 1994 Mazda Protege DX. It is pretty simple to do. The parts are numbered in the image. Remove them in the order they are numbered and put them back on in reverse order. I listed it step-by-step below.If you have any questions you can PM me.

http://www.protegeclub.com/attachmen...1&d=1179027242

Part List

• Resonance chamber
• Coolant fan motor connector
• Radiator thermoswitch connector (AT Only)
• Coolant reservoir hose
• Radiator hose
• ATF cooler hose (AT Only)
• Radiator bracket
• Radiator
• Coolant fan

Step 1. Remove Radiator Cap(Make sure engine is cool)

Step 2. Remove radiator plug to drain radiator fluid. (The plug is located on the bottom drivers side of the radiator. There will be a hole in your splash gaurd exposing it. Mine was on there crazy tight, I needed a hammer and screw driver to turn it. I didn't have to worry about breaking mine becuase my new radiator came with one already. If your's does not the try to be carefull with it as it is made from plastic)

Step 3. Remove the Resonance Chamber (Part Number 1 in image)

Step 4. Remove Collant Fan Motor Connector (Part Number 2 in image) I used a small plastic bag and rubber band to cover the end to make sure it didn't get wet.

Step 5. (For Automatic trany only) Remove Radiator Thermoswitch Connector (Part Number 3 in image)

Step 6. Remove Coolante Resevoir Hose (Part Number 4 in image)

Step 7. Remove upper Radiator hose (Part Number 5 in image marked with A) The clamps are a little tricky as you need to compres them to remove them. I would suggest using a vice grip.

Step 8. Remove lower Radiator hose from radiator only. (Part Number 5 in image marked with B) I found it was hard to remove the hose from the engine with the radiator still in. You will be able to access the lower radiator hose from underneth the car through the splach gaurd. I removed my splash gaurd as I felt it was in the way. If you remove it don't forget to put it back on when your done. Be careful as some fluid may come out of the hose when you are removing it.

Step 9. (For Automatic trany only) Remove the ATF cooler hose from bottom of radiator. (Part Number 6 in image)

Step 10. Remove the two radiator brackets. (Part Number 7 in image) Do note the radiator will tilt back towards the engine when you remove the brackets.

Step 11. Remove the radiator. (Part Number 8 in image) The radiator should just lift right out at this point. There are two rubber feet on the bottom of the radiator, keep an eye on them as they are not perminantly attached to the radiator and may slip off when you are pulling it out.

Step 12. Remove the Coolant Fan from the radiator. (Part Number 9 in image) The radiator is held onto the radiator by four bolts or screws. Two at top and two at bottom.

Step 13. If you are replacing the hoses along with the radiator then you will need to remove the lower radiator hose from the engine at this point. Be careful as the hose is right next to a coolent line if you have AC in your car. It is a tight spot and you will definately need to work with it a little to get it out.

Step 14. Put everything back together. Just follow the steps in reverse. Don't forget to fill the radiator and coolant reservoir once you are done. My radiator took about 1 1/2 galons to fill between spillage and the coolant reservoir.