Radiator Service

REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE BATTERY AND BATTERY TRAY
4. DISCONNECT HOSES
Disconnect these hoses:





(1) Upper radiator hose from radiator
(2) Radiator reservoir hose from radiator





(3) Lower radiator hose from radiator
(4) 2 oil cooler hoses for AIT from radiator, Plug the hose ends.

HINT: At the time of installation, please refer to the following items. Check the A/T fluid level.





5. REMOVE NO.2 FAN SHROUD
a) Remove the 2 clips.
b) Disconnect the claw of the No.2 fan shroud from the hook of the No.1 fan shroud, and remove the No.2 fan shroud.

HINT: Insert the claw to the hook as shown.





6. REMOVE RADIATOR ASSEMBLY
a) Remove the 2 bolts, screw and upper radiator support. Remove the 2 upper radiator supports.
Torque: (Bolt) 12 Nm (120 kgf-cm, 9 ft. lbs.)
b) Lift out the radiator assembly.
c) Remove the 2 lower radiator supports.





7. REMOVE NO.1 FAN SHROUD FROM RADIATOR
a) Remove the 2 bolts and fan shroud.
b) Remove the 2 cushions from the fan shroud.

DISASSEMBLY
1. REMOVE DRAIN HOSE
2. REMOVE PACKINGS
Remove the 5 packings from the radiator.





3. ASSEMBLY OF 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

NOTICE: Do not raise the lock plate higher than horizontal.





5. 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.





6. REMOVE OIL COOLER FROM LOWER TANK
a) Remove the pipes.

HINT: 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.

REASSEMBLY
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), and nuts (5).
Torque: 8.3 Nm (85 kgf-cm, 74 inch lbs.)





e) Install the pipes (6).
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)

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





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.
- First correct any deformation with pliers or similar object if necessary. 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. ASSEMBLY OF 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 (0.331 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 bolt.
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 for cannot be staked with SST. Use wrap vinyl tape around the tip of a pair of 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 (H): 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. INSPECT FOR WATER LEAKS
a) Tighten the drain cock.





b) Plug the inlet and outlet pipes of the radiator with SST.
SST 09230-01010
c) Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi)





d) Inspect for water 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 performing the water leak test, first switch the radiator around in the water until all air bubbles disappear.

7. INSTALL PACKINGS
Install 5 new packings to the radiator.
8. INSTALL DRAIN HOSE

INSTALLATION
Installation is in the reverse order of removal.