Radiator Outer Tank (In Tank Oil Cooler) Installation Note

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

NOTE:

The old O-ring must be replaced.

Fig 1: Locating Radiator Outer Tank O-Ring

Courtesy of MAZDA MOTORS CORP.

Install a new O-ring and ensure it is not twisted.
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.

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 removal procedure.
1. Tighten the lock nut on the adjusting screw against the handle to lock the adjustment in place.
  
  Fig 2: Turning Adjusting Screw To Position
  Courtesy of MAZDA MOTORS CORP.
Squeeze the header tabs down in order as shown against the lip of radiator outer tank base with locking-type pliers while rotating the pliers toward the tank.

Fig 3: Header Tab Squeezing Pattern
Courtesy of MAZDA MOTORS CORP.
Verify the height of the header tabs is same as the height before removal.
Inspect for the leakage of radiator according to the following procedure.
1. Cover the radiator inlet and outlet.
2. Cover the ATF cooler inlet and outlet.
3. Connect a radiator tester.
  
  Fig 4: Verifying Height Of Header Tabs
  Courtesy of MAZDA MOTORS CORP.
4. Apply pressure of 145 kPa {1.5 kgf/m ² , 21 psi} and verify that the pressure is held.
  
  Fig 5: Pressure Testing Radiator
  Courtesy of MAZDA MOTORS CORP.
5. Put the radiator into water slowly with the radiator tester connected.
6. Inspect for air leakage.
  
  Fig 6: Checking Radiator For Air Leakage
  Courtesy of MAZDA MOTORS CORP.