Overhaul

RADIATOR

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4) (without Hose):

COMPONENTS (Part 5) (With Hose):

DISASSEMBLY
1. REMOVE DRAIN PLUG
(a) Remove the drain plug.
(b) Remove the O-ring.

2. REMOVE RADIATOR TANK UPPER
(a) Install the claw to the overhaul handle, inserting it in the hole in part A as shown in the illustration.
SST 09230-01010 (09231-01010, 09231-01030)
(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 in.)

NOTICE: If the stopper bolt is not adjusted, the claw may be damaged.

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

(d) Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft-faced hammer and remove the tank.
(e) Remove the O-ring.

3. REMOVE RADIATOR TANK LOWER
(a) With hose:
(1) Remove the bolt, 2 clips and hose from the radiator assembly.
(b) Removal procedure of the radiator tank lower is the same as that of the radiator tank upper.

(c) Without hose:
(1) Remove the bolt and cooler pipe (A).
(2) Remove the nut and plate washer (B).
(3) Remove the oil cooler (C).
(4) Remove the 2 O-rings from the oil cooler (D).

INSPECTION

1. INSPECT LOCK PLATE
(a) Inspect the lock plate for damage.

HINT:
^ If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Therefore, first correct the shape of the lock plate groove with pliers or a similar object, if necessary.
^ Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace the locking plate if necessary.

NOTICE: The radiator can only be recaulked 2 times. After recaulking 2 times, the radiator core must be replaced.

REASSEMBLY

1. INSTALL RADIATOR TANK UPPER
(a) Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration.
SST 09230-01010, 09231-14010

(b) After checking that there are no foreign objects in the lock plate groove, install a new O-ring without twisting it.

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

(d) 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.

HINT:
^ Do not tap the areas protruding around the pipes, brackets or tank ribs.
^ The dotted circles shown in the illustration and parts of the oil cooler near the dotted circles cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates.

(e) Check the lock plate height (H) after completing caulking.
Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.)
If not within the specified height range, adjust the stopper bolt of the handle and caulk again.
(f) Tap the lock plate with a soft-faced hammer so that there is no gap between the lock plate and the tank.

2. INSTALL RADIATOR TANK LOWER
(a) Without hose:
(1) Clean the O-ring contact surfaces of the lower tank and oil cooler.
(2) Install 2 new O-rings to the oil cooler (D).
(3) Install the oil cooler to the lower tank (C).
(4) Install the plate washer and nut (B).
Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf)
(5) Install the cooler pipe with the bolt (A).
Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf)
(b) Installation procedure of the radiator tank lower is the same as that of the radiator tank upper.

(c) With hose:
(1) Install the hose with the bolt and 2 clips.
Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf)

3. INSTALL DRAIN PLUG
(a) Install a new O-ring to the drain plug.
(b) Install the drain plug.

4. INSPECT FOR WATER LEAKS
(a) Plug the inlet and outlet pipes of the radiator with SST.
SST 09230-01010
(b) Using the 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 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. Therefore, before doing the water leak test, first swish the radiator around in the water until all air bubbles disappear.