Saturday, July 2, 2011

how to replace thermostat on 2003 mazda mpv

The thermostat located in a removable housing at the engine end of the upper radiator hose

Drain about 1 gallon of coolant from the radiator
Remove this housing
Make note how thermostat is installed
Clean both surfaces
Replace thermostat and gasket
Re-fill coolant slowly to prevent an air lock
Start engine and look for leaks
Run engine to normal operating temperature with heater on
Re-check coolant level


  1. Remove the thermostat housing.
  2. Remove the three bolts and separate the water outlet adapter from the thermostat housing.
    NOTE
    The thermostat is indexed and must be installed correctly.

  3. Remove the thermostat and the O-ring seal.
    NOTE
    Clean and inspect the sealing surfaces.

  4. To install, reverse the removal procedure. Torque all fasteners to 89 inch lbs. (10 Nm).
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Water Pump

Removal & Installation


  1. Before servicing the vehicle, refer to the Precautions section.
  2. Drain the cooling system.
  3. Remove or disconnect the following:

    Battery and tray
    Water pump drive belt
    Water pump drive pulley
    Thermostat housing
    Water pump belt tensioner
    Oil cooler hose
    Water outlet pipe
    Water pump


To install:

  1. Install or connect the following:

    Water pump. Tighten the bolts to 89 inch lbs. (10 Nm) plus 90 degrees.
    Water outlet pipe
    Oil cooler hose
    Water pump belt tensioner
    Thermostat housing
    Water pump drive pulley
    Water pump drive belt
    Battery and tray

  2. Fill the cooling system.
  3. Start the engine and check for leaks.

2.5L Engine



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

    Battery and tray
    Water pump drive belt
    Water pump drive pulley
    Thermostat housing
    Water pump belt tensioner
    Oil cooler hose
    Water outlet pipe
    Water pump


To install:

  1. Install or connect the following:

    Water pump. Tighten the bolts to 89 inch lbs. (10 Nm) plus 90 degrees.
    Water outlet pipe
    Oil cooler hose
    Water pump belt tensioner
    Thermostat housing
    Water pump drive pulley
    Water pump drive belt
    Battery and tray

  2. Fill the cooling system.
  3. Start the engine and check for leaks.

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Drain the cooling system.
  3. Remove or disconnect the following:

    Negative battery cable
    Drive belt
    Fan clutch and shroud
    Water pump pulley
    Heater hose from the water pump inlet tube
    Lower radiator hose
    Water pump inlet tube
    Water pump and discard the gasket

    Click image to see an enlarged view

    Fig. Exploded view of the water pump 2.5L engines



To install:

  1. Clean the mating surface with the water pump connects to the engine.
  2. Install or connect the following:

    Water pump with a new O-ring. Torque the bolts to 15 ft. lbs. (20 Nm).
    Inlet tube. Torque the bolts to 89 inch lbs. (10 Nm).
    Lower radiator hose
    Water pump pulley
    Heater hose from the water pump inlet tube
    Fan clutch and shroud
    Drive belt
    Negative battery cable

  3. Fill the cooling system.
  4. Start the vehicle and check for leaks, repair if necessary.

3.0L Engine





Click image to see an enlarged view

Fig. Exploded view of the water pump assembly-3.0L engine

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

    Negative battery cable
    Air intake assembly
    Upper radiator hose
    Accessory drive belts
    Cooling fan and shroud
    Front cover
    Timing belt. Refer to the Timing Belt unit repair section.
    Water pump


To install:

  1. Install or connect the following:

    Water pump. Tighten the fasteners to 14-18 ft. lbs. (19 -25 Nm).
    Timing belt
    Front cover
    Cooling fan and shroud
    Accessory drive belts
    Upper radiator hose
    Air intake assembly
    Negative battery cable

  2. Fill the cooling system.
  3. Start the engine and check for leaks.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the cooling system.
  3. Remove or disconnect the following:

    Battery and tray
    Water pump drive belt
    Water pump drive pulley
    Thermostat housing
    Water pump belt tensioner
    Oil cooler hose
    Water outlet pipe
    Water pump


To install:

  1. Install or connect the following:

    Water pump. Tighten the bolts to 89 inch lbs. (10 Nm) plus 90 degrees.
    Water outlet pipe
    Oil cooler hose
    Water pump belt tensioner
    Thermostat housing
    Water pump drive pulley
    Water pump drive belt
    Battery and tray

  2. Fill the cooling system.
  3. Start the engine and check for leaks

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Radiator

Removal & Installation


  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. Drain and recycle the engine coolant.
  4. Raise and support the vehicle.
  5. Remove the lower splash shields.
  6. Disconnect the lower radiator hose and the degas return hose.
  7. Remove the lower center support bolt.
  8. Lower the vehicle.
  9. Disconnect the remaining coolant hose connections.
  10. Position the hood latch assembly out of the way.
  11. Remove the two bolts and the center support.
  12. Remove the two top bolts retaining the cooling fan to the radiator.
  13. Remove the upper radiator support brackets, and remove the radiator from the vehicle.
  14. To install, reverse removal procedure. Tighten all fasteners to 89 inch lbs. (10 Nm).
  15. Start the engine and check for leaks, repair if necessary.

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