Overhaul

RADIATOR ASSEMBLY
OVERHAUL
1. REMOVE PACKINGS
2. REMOVE RADIATOR CAP SUB-ASSEMBLY
3. REMOVE DRAIN PLUG
a. Remove the drain plug.
b. Remove the O-ring.





4. ASSEMBLE SST
SST 09230-01010
a. Install the claw to the overhaul handle, inserting it in the hole in part A as shown in the illustration.
b. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration.
Dimension B : 0.2 to 0.3 mm (0.008 to 0.012 inch)

NOTICE: If this adjustment is not performed, the claw will be damaged.





5. UNCAULK LOCK PLATE
Using SST to release the caulking, grip the handle until stopped by the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01030)





6. REMOVE RADIATOR TANK UPPER AND TANK LOWER
a. Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a plastic hammer and remove the tank.
b. Remove the O-ring.





7. REMOVE OIL COOLER ASSEMBLY
a. Remove the 2 inlets.
b. Remove the 2 nuts, 2 plate washers and oil cooler.
c. Remove the 2 O-rings from the oil cooler.





8. INSTALL OIL COOLER ASSEMBLY
a. Install 2 new O-rings to the oil cooler.
b. Install the oil cooler to the lower tank with the 2 plate washers and 2 nuts.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
c. Install the 2 inlets.
Torque: 14.7 Nm (150 kgf-cm, 11 ft. lbs.)





9. INSPECT LOCK PLATE FOR DAMAGE
Inspect the lock plate for damage.

HINT:
^ If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Correct any de formations with pliers.
^ Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace if necessary.

NOTICE: The radiator can only be recaulked twice. After the 2nd time, the radiator core must be replaced.

10. INSTALL RADIATOR TANK UPPER AND TANK LOWER





a. Check that there are no foreign objects in the lock plate groove, and install a new O-ring. Make sure the O-ring is not twisted.

HINT: When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it.





b. Install the tank without damaging the O-ring.
c. Tap the lock plate with a plastic hammer so that there is no gap between the lock plate and the tank.





11. ASSEMBLE SST
SST 09230-01010, 09231-14010
a. Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration.
b. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration.
Dimension B: 8.4 mm (0.331 inch)
12. CAULK LOCK PLATE





a. Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate.
SST 09230-01010

HINT:





^ Do not tap the areas protruding around the ports (1), flange (2) and brackets (3).





^ The points shown in the illustration cannot be tapped with SST. Use pliers and be careful not to damage the core plates.





b. Check the lock plate height (H) after completing the caulking.
Plate height (H): 8.8 mm (0.346 inch)
If not within the specified height, adjust the stopper bolt of the handle again and caulk the lock plate again.
13. INSTALL DRAIN PLUG
a. Install a new O-ring to the drain plug.
b. Install the drain plug.
14. INSPECT FOR WATER LEAKS





a. Plug the inlet and outlet pipes of the radiator with SST
SST 09230-01010
b. Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi)
c. Submerge the radiator in water.





d. Inspect for leaks.

HINT: On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Before doing the water leak test, first shake the radiator in the water until all air bubbles disappear.

15. INSTALL RADIATOR CAP SUB-ASSEMBLY
16. INSTALL PACKINGS