Radiator Outer Tank (In Tank Oil Cooler) Assembly Note

WARNING: This page is about a different car, the 2004 Mazda RX-8. 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.

Fig 1: Locating Radiator Outer Tank O-Ring
Courtesy of MAZDA MOTORS CORP.
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.
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 Jaws Against Drill Bit
Courtesy of MAZDA MOTORS CORP.
Squeeze the header tabs down in the order as shown in the figure against the lip of the radiator outer tank base with the locking-type pliers while rotating the pliers toward the tank.

Fig 3: Squeezing Order Of Header Tabs Down
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.