Radiator Lower Tank (In Tank Oil Cooler) Installation Note

WARNING: This page is about a different car, the 2003 Mazda Protege5 and 2003 Mazda Protege. 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: Installing New 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 removal procedure.
- Tighten the lock nut on the adjusting screw against the handle to lock the adjustment in place.
  
  Fig 2: Tightening Lock Nut On Adjusting Screw
  Courtesy of MAZDA MOTORS CORP.
Squeeze the header tabs down in order as shown against the lip of radiator lower tank base with locking-type pliers while rotating the pliers toward the tank.

Fig 3: Squeezing Header Tabs Lip Of Radiator Lower Tank Base With Locking-Type Pliers
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. Blind the radiator inlet and outlet.
2. Blind the ATF cooler inlet and outlet.
3. Connect a radiator tester.
  
  Fig 4: Identifying Height Of Header Tabs
  Courtesy of MAZDA MOTORS CORP.
4. Apply pressure of 150 kPa {1.5 kgf/m ² , 21 psi} and verify that the pressure is held.
  
  Fig 5: Applying Pressure
  Courtesy of MAZDA MOTORS CORP.
5. Put the radiator into water slowly with the radiator tester connected.
6. Inspect for air leakage.
  
  Fig 6: Putting Radiator Into Water Slowly With Radiator Tester Connected
  Courtesy of MAZDA MOTORS CORP.