Radiator Service

REMOVAL

HINT:
^ AT the time of installation, please refer to the following items.
^ Start the engine, and check for coolant and A/T fluid leaks.
^ Check the A/T fluid level.

1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE A/C CONDENSER





4. REMOVE RADIATOR ASSEMBLY
a. Disconnect these connectors and hoses:
^ No.1 electric cooling fan connector
^ No.2 electric cooling fan connector
^ No.1 ECT switch connector
^ Upper radiator hose from radiator
^ Lower radiator hose from radiator
^ Radiator reservoir hose
^ 2 oil cooler hoses from radiator
b. Remove the 2 bolts and 2 upper radiator supports.
Torque: 12.8 Nm (130 kgf-cm, 9 ft. lbs.)
c. Lift out the radiator assembly.
d. Remove the 2 lower radiator supports.
5. REMOVE ELECTRIC COOLING FAN FROM RADIATOR
Remove the 6 bolts and cooling fan.
Torque: 5.0 Nm (50 kgf-cm, 44 inch lbs.)

DISASSEMBLY





1. REMOVE NO.1 ECT SWITCH
a. Remove the No.1 ECT switch.
b. Remove the O-ring.
2. REMOVE DRAIN PLUG
a. Remove the drain plug.
b. Remove the O-ring.





3. 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 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).

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





4. UNCAULK LOCK PLATES
Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt.
SST 09230-01010





5. REMOVE TANKS AND O-RINGS
Lightly tap the bracket of the radiator (or radiator inlet or outlet) with a soft-faced hammer, and remove the tank and the O-ring.





6. REMOVE OIL COOLER FROM LOWER TANK
a. Loosen the nut, and remove the cooler pipe. Remove the 2 cooler pipes.
b. Remove the 2 nuts and plate washers.
c. Remove the oil cooler and 2 O-rings.

REASSEMBLY





1. INSTALL OIL COOLER TO LOWER TANK
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 nuts.
Torque: 8.3 Nm (85 kgf-cm, 74 inch lbs.)
c. Install the cooler pipe in the direction indicated in the illustration.
Torque: 14.7 Nm (150 kgf-cm, 11 ft. lbs.)





2. INSPECT 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 any deformation with pliers or similar object. Water leakage will result if the bottom of the lock plate groove is damaged or dented.

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

3. 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.

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





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





4. 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: 8.4 mm (0.331 inch)
5. 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 squeezing the handle until stopped by the stopper plate.
SST 09230-01010

HINT:





^ Do not stake the areas protruding around the pipes, brackets or tank ribs.





^ The points shown in the illustration and oil cooler near here cannot be staked with the 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: 7.40 - 7.80 mm (0.2913 - 0.3071 inch)
If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
6. INSTALL NO.1 ECT SWITCH
a. Install a new O-ring to the No.1 ECT switch.
b. Install the No.1 ECT switch.
7. INSTALL DRAIN PLUG
a. Install a new O-ring to the drain plug.
b. Install the drain plug.
8. 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. Therefore, before doing the water leak test, first swish the radiator around in the water until all air bubbles disappear.

INSTALLATION
Installation is in the reverse order of removal.