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. DRAIN ENGINE COOLANT
2. REMOVE RADIATOR SUPPORT UPPER SEAL
3. DISCONNECT RELAY BLOCK (FOR DAYTIME RUNNING LIGHT SYSTEM) FROM BATTERY HOEDOWN CLAMP
4. DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR
5. DISCONNECT LOWER RADIATOR HOSE FROM WATER INLET PIPE
6. DISCONNECT A/T OIL COOLER HOSES FROM OIL COOLER PIPES
7. DISCONNECT NO.1 AND NO.2 COOLING FAN CONNECTORS
8. DISCONNECT NO.1 ECT SWITCH WIRE CONNECTOR





9. REMOVE RADIATOR AND COOLING FANS ASSEMBLY
a. Remove the 2 bolts and 2 upper supports
Torque: 12.8 Nm (130 kgf-cm, 9 ft. lbs.)
b. Lift out the radiator, and remove the radiator and cooling fans assembly
c. Remove the 2 lower supports





10. REMOVE A/T OIL COOLER HOSES FROM RADIATOR
11. REMOVE LOWER RADIATOR HOSE FROM RADIATOR





12. REMOVE NO.1 ECT SWITCH





13. REMOVE NO.1 COOLING FAN FROM RADIATOR
Remove the 2 bolts and cooling fan.
Torque: 5.0 Nm (50 kgf-cm, 44 inch lbs.)
14. REMOVE NO.2 COOLING FAN FROM RADIATOR
Remove the 3 bolts and cooling fan.
Torque: 5.0 Nm (50 kgf-cm, 44 inch lbs.)

DISASSEMBLY





1. REMOVE CUSHION FROM RADIATOR
2. 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 - 0.5 mm (0.008 - 0.020 inch).

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





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





4. REMOVE BANKS AND O-RINGS
a. Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft-faced hammer and remove the bank.
b. Remove the O-ring.





5. REMOVE OIL COOLER FROM LOWER BANK
a. Remove the pipe.
b. Remove the nuts and plate washers.
c. Remove the oil cooler and O-rings.

REASSEMBLY





1. INSTALL OIL COOLER TO LOWER BANK
a. Clean the O-ring contact surface of the lower bank and oil cooler.
b. Install a new O-rings (1) to the oil cooler (2).
c. Install the oil cooler with the O-rings to the lower bank (3).
d. Install the plate washers (4), and nuts (5). Torque the nuts.
Torque: 8.3 Nm (85 kgf-cm, 74 inch lbs.)
e. Install the pipe (6).
Torque: 14.7 Nm (150 kgf-cm, 11 ft. 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 bank 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 BANKS





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 bank 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 bank.





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": 8.4 mm (0.34 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 bank 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 (Hi) 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.
6. INSTALL CUSHION

INSTALLATION
Installation is in the reverse order of removal.