Radiator Outer Tank (In Tank Oil Cooler) Installation Note

WARNING: This page is about a different car, the 2004 Mazda 6. However, it is still accessible from the selected car via links, so may be relevant.

Install a new O-ring and ensure it is not twisted.
NOTE:
- The old O-ring must be replaced.
Position the radiator tank in the original direction to the core using care not to scratch the tank sealing surface with the header tabs.
NOTE:
- Step 3 will set jaw opening to the correct specification.
Fig 1: Identifying Radiator Outer Tank O-Ring
Courtesy of MAZDA MOTORS CORP.
With the jaws of locking-type pliers (vise grips) closed and locked, turn the adjusting screw to position the jaws against the drill bit with the diameter measured (height) in the removal procedure 1. Tighten the lock nut on the adjusting screw against the handle to lock the adjustment in place.

Fig 2: Gripping Drill Bit With Help Of Locking Type Pliers
Courtesy of MAZDA MOTORS CORP.
Squeeze the header tabs down in the order as shown against the lip of the radiator outer tank base with the locking-type pliers while rotating the pliers toward the tank.

Fig 3: Squeezing Header Tabs Down In Proper Order
Courtesy of MAZDA MOTORS CORP.
Verify that the height of the header tabs is same as the height before removal.
Inspect for leakage from radiator. (See ENGINE COOLANT LEAKAGE INSPECTION .)

Fig 4: Verifying Height Of Header Tabs

Courtesy of MAZDA MOTORS CORP.