Disassembly and Assembly

DISASSEMBLY
1. REMOVE PACKINGS





a. Remove the 2 packings from the radiator front side.





b. Remove the 4 packings from the radiator rear side.
2. REMOVE ECT SWITCH FOR A/C COOLING FAN
a. Remove the ECT switch.
b. Remove the O-ring from the ECT switch.
3. REMOVE DRAIN PLUG
a. Remove the drain hose.
b. Remove the drain plug.
c. Remove the O-ring from the drain plug.





4. ASSEMBLE SST
SST 09230-01010
a. Install the claw to the overhaul handle, inserting it in A811, 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.





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





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.





7. REMOVE OIL COOLER FROM LOWER TANK
a. Remove the 2 nuts and 2 plate washers.
b. 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.
c. Install the 2 plate washers and 2 nuts.
Torque: 8.34 Nm (85 kgf.cm, 74 inch lbs.)





2. INSPECT LOCK PLATE
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 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.

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" shown in the diagram.
Dimension "B": 8.8 mm (0.35 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 bolt.
SST 09230-01010








HINT:
^ 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. Use pliers or similar object and be careful not to damage the core plates.





b. Check the lock plate height after completing the Caulking.
Plate height (H): 7.40 - 7.80 mm (0.2959 - 0.3119 inch)
If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
6. PAINT LOCK PLATES





7. INSTALL ECT SWITCH FOR A/C COOLING FAN
a. Install a new O-ring to the ECT switch.
b. Apply soapy water to the O-ring.
c. Install the ECT switch.
Torque: 7.4 Nm (75 kgf.cm, 65 inch lbs.)
8. 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.
d. Install the drain hose.





9. INSTALL PACKINGS
a. Install 4 new packings to the radiator rear side.
b. Install 2 new packings to the radiator front side.