Disassembly and Assembly

DISASSEMBLY






1. Remove the two packings from the radiator front side and the four packings from the radiator rear side.
2. Remove the Engine Coolant Temperature (ECT) switch, then remove and discard the O-ring from the ECT switch.
3. Remove the drain hose, then the drain plug and discard the O-ring from the drain plug.




4. Assemble the radiator service tool set, Special Service Tool (SST) No. 09230-01010, or equivalent as follows:
(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 in).

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




5. Using SST radiator service tool set, release the caulking, by squeezing the handle until stopped by the stopper bolt.




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




7. Remove the two nuts and two plate washers from oil cooler, then lift oil cooler and two O-rings from lower tank.


ASSEMBLY



1. Place two new O-rings on the oil cooler, then install the oil cooler to the lower tank using the two plate washers and two nuts.
Torque: 8.34 Nm (85 kg.cm 74 in. lbs.).




2. Inspect the lock plate for damage.

NOTES:
^ 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. Therefore, repair or replace if necessary.
^ The radiator can only be recaulked two times. After the 2nd time, the radiator core must be replaced.

3. Install new O-rings and tanks as follows:



(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.



(c) Tap the lock plate with a soft-faced hammer so that there is no gap between it and the tank.

4. Assemble SST radiator service tool set as follows:



(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 diagram.
Dimension "B": 8.4 mm (0.34 in).




5. Lightly press SST radiator service tool set 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, brackets or tank ribs.




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




^ Check the lock plate height (H) after completing the caulking.
Plate height (H): 7.40-7.80 mm (0.2959-0.3119 in).

^ If not within the specified height, adjust the stopper bolt of the handle again and caulk again.

6. Paint lock plates.




7. Install a new O-ring to the ECT switch, then apply soapy water to the O-ring and install the ECT switch.
Torque: 7.4 Nm (75 kg.cm, 65 in.lb).

8. Install a new O-ring to the drain plug, then apply soapy water to the O-ring and install the drain plug and drain hose.




9. Install four new packings to the radiator rear side and two new packings to the radiator front side.