Tools You'll Likely Need:
* Repair Manual: Absolutely essential for specific location, procedures, and torque specs.
* Socket Set: Various sizes, including the one that fits the freeze plug. You might need a deep well socket.
* Hammer: A ball-peen hammer is ideal.
* Punch: A slightly smaller diameter than the freeze plug to help get it started. A slightly larger punch might be needed to tap the new plug in.
* Screw Driver (possibly): For removing any interfering parts.
* Penetrating Oil (PB Blaster or similar): To help loosen any rusted plugs.
* Rags or Shop Towels: To clean up coolant spills.
* Coolant: To refill the cooling system after the repair.
* Jack and Jack Stands (or ramps): To safely access the underside of the vehicle.
* Drain Pan: To catch coolant.
* Gloves: To protect your hands.
* New Freeze Plug(s): Make sure to get the correct size and type.
Procedure (General Steps – Consult your repair manual for specifics):
1. Safety First: Disconnect the negative battery cable. This prevents accidental shorts. Jack up the car and securely support it with jack stands.
2. Drain the Coolant: Locate the coolant drain plug (usually on the radiator or engine block). Drain the coolant into a suitable container.
3. Access the Freeze Plug: This will depend on the location of the failed freeze plug. You may need to remove other components to gain access. The repair manual will show you the exact location and any necessary disassembly.
4. Remove the Old Freeze Plug: Apply penetrating oil around the freeze plug and let it sit for a while. Using a punch slightly smaller than the freeze plug, carefully tap it out from the inside. Be gentle to avoid damaging the engine block. Sometimes, a freeze plug can be pushed from the outside. Sometimes it's easier to break it up with a punch and chisel and remove the pieces.
5. Clean the Area: Thoroughly clean the area around the freeze plug hole to remove any rust or debris.
6. Install the New Freeze Plug: Lubricate the new freeze plug with a light coat of oil or grease. Carefully tap the new freeze plug into place using a socket that fits the outside of the plug and a hammer. Do not use excessive force. The plug should sit flush with the engine block. Again, your repair manual will give you the proper installation method.
7. Reassemble: Reinstall any components you removed to access the freeze plug.
8. Refill and Bleed the Cooling System: Refill the cooling system with the correct type and amount of coolant. Bleed the air out of the system according to your repair manual's instructions. This is crucial to prevent overheating.
9. Test: Run the engine and check for leaks.
Important Considerations:
* Rust: Rust can make removing freeze plugs extremely difficult. Be patient and use penetrating oil liberally.
* Engine Block Damage: If you damage the engine block while removing a freeze plug, you'll have a much more serious problem.
* Coolant Type: Use the correct type of coolant for your Mazda Protege.
* Torque: Use the correct torque specification from your repair manual when reinstalling any bolts or components.
This is a general guide. You absolutely must consult a repair manual specific to your 1991 Mazda Protege before attempting this repair. If you're not comfortable working on your car, it's best to take it to a qualified mechanic. Improper repair could lead to serious engine damage.
