A/T

DISASSEMBLY
1. Assemble radiator Special Service Tool (SST) 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 inch0.

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

2. Uncaulk lock plates using radiator SST to release the caulking, squeeze the handle until stopped by the stopper bolt.

3. Lightly tap the radiator hose inlet (or outlet) with a soft-faced hammer and remove the tank.
4. Remove the O-ring.

5. Remove oil cooler from lower tank.
(a) Remove the pipes.

NOTE: Make a note of the direction to face the pipes.

(b) Remove the nuts, spring washers, plate washers and oil cooler.
(c) Remove the O-rings from the oil cooler.

ASSEMBLY
1. Install oil cooler to lower tank.
(a) Clean the O-ring contact surface of the lower tank and oil cooler.
(b) Install new O-rings (1) to the oil cooler (2).
(c) Install the oil cooler (2) to the lower tank (3).
(d) Install the plate washers (4), spring washers (5) and nuts (6) and torque to 8.3 Nm (74 inch lbs.).
(e) Install the pipes (7) and torque to 15 Nm (11 ft. lbs.).

NOTE: Face the pipes in the same direction they were before disassembly.

2. Inspect the lock plate for damage as follows:
- Correct any deformation with pliers or similar object.
- Water leakage will result if the bottom of the lock plate groove is damaged or dented.
- Repair or replace if necessary.

NOTE:
- If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible.
- The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.

3. Using new O-rings Install the 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.

4. Assemble the radiator SST 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" shown in the diagram is 8.4 mm (0.331 inch).

5. Caulk lock plate as follows:
(a) Lightly press radiator SST against the lock plate in the order shown in the illustration.
(b) After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper plate.

NOTE:
- 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 SST.

- Use pliers or similar object and be careful not to damage the core plates.

(c) Check the lock plate height (H) after completing the caulking.
Plate height: 7.40-7.80 mm (0.2913-0.3071 inch).
(d) If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
6. Inspect for water leaks as follows:
(a) Tighten the drain plug.

(b) Plug the inlet and outlet pipes of the radiator with stoppers of SST 09230-01010, or equivalent.
(c) Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 177 kPa (26 psi).

(d) Using a suitable water bath inspect for leaks.

NOTE: 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, move the radiator around in the water until all air bubbles disappear.

7. If the water leak test checks out okay, allow the radiator to completely dry and then paint the lock plates.
8. Install drain hose to radiator.
9. Install reservoir inlet pipe to radiator.