I am replacing my cylinder head and doing the balance shaft seals, o'rings, bearings and oil cooler seals while I am in there.

I am putting the oil cooler back into the housing with the correct green o'rings and I am having a very hard time getting the cooler all the way in. The new o'ring gives quite a lot of resistance. I put some oil on it before I started so it is not dry. I was wondering if a large C clamp would be ok to get it the rest of the way on?

 

I was able to put it back using only hands. There were some resistance, but it was just sure push. Are Your sure You put all of spacers, shims correltly before assembly ?

 

I pushed on it with most of my weight through a block of wood and it goes in very slowly. Interesting to know that yours went in by hand.

I have the tech service bulletin from which I am following directions. I have the plastic washer in place.

 

I didn't need to exert undue force to get it to seat properly. If I recall correctly, the cooler does not just drop in entirely flush with the housing because the bushings exert some tension which is taken up when the housing is tightened to the block. It may be the case that your application does not require the plastic washer. Did your old cooler have the washer installed?