Disassembly and Assembly

DISASSEMBLY
1. Remove No. 1 fan shroud.
Remove the 4 bolts and No. 1 fan shroud.
2. Remove radiator supports.
3. Remove drain plug.

4. Assemble Special Service Tool (SST) Radiator Service Tool Set # 09230 - 01010 or equivalent.
(a) Install the claw to the overhaul handle, inserting it in the hole in part "A" as shown in the diagram.
(b) While gripping the handle, adjust the stopper bolt so that dimension "B" shown in the diagram is 0.2 - 0.3 mm (0.008 - 0.012 inch).

CAUTION: If this adjustment is not done, the claw may be damaged.

5. Uncaulk lock plates.
Using SST Radiator Service Tool Set # 09230 - 01010 or equivalent to release the caulking, squeeze the handle until stopped by the stopper bolt.
6. Remove tanks and O-rings.

(a) Lightly tap the radiator port (inlet or outlet) with a soft-faced hammer, and remove the tank.
(b) Remove the O-ring.

REASSEMBLY

1. Inspect lock plate.
Inspect the lock plate for damage.

NOTE: If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible.

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

2. Install new O-rings and tanks.

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

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

(b) Install the tank without damaging the O-ring.

3. Assemble SST Radiator Service Tool Set # 09230 - 01010 or equivalent.
(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" shown in the diagram.
Dimension "B": 8.4 mm (0.34 inch)
4. Caulk lock plate.

(a) Lightly press SST Radiator Service Tool Set # 09230 - 01010 or equivalent against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper bolt.

NOTE:

^ Do not stake the areas protruding around the ports.

^ The points shown in the rib sides near here cannot be staked with SST. Use pliers or similar object and be careful not to damage the core plates.

(b) Check the lock plate height (H) after completing the caulking.
Plate height (H): 7.4 - 7.8 mm (0.2959 - 0.3119 inch)
If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
5. Paint lock plates.
6. Install drain plug to radiator.
(a) Install a new O-ring to the drain plug.
(b) Apply soapy water to the O-ring.
(c) Install the drain plug.
7. Check for water leaks.

(a) Using SST Radiator Service Tool Set # 09230 - 01010 or equivalent, plug the inlet and outlet pipes of the radiator.
(b) Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 177 kPa (26 psi)

(c) Check for water leaks.

NOTE: On radiators with resin tanks, there is a clearance between the core plate and tank where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before performing the water leak test, first swirl the radiator around in the water until all air bubbles disappear.

8. Install supports.
Torque: 12.7 Nm (9 ft. lbs.)
9. Install No. 1 fan shroud.