Radiator Service

REMOVAL
1. REMOVE ENGINE UNDER COVERS
2. DRAIN ENGINE COOLANT
3. DISCONNECT HOSES





a) Disconnect the upper radiator hose from the radiator.
b) Disconnect the radiator reservoir hose.





c) Disconnect the lower radiator hose from the radiator.
d) Disconnect the 2 oil cooler hoses (for transmission) from the radiator.

HINT: Plug the hose ends.





e) Remove the union bolt and gasket, disconnect the pressure hose from the hydraulic motor.
f) Disconnect the return hose from the hydraulic motor.
4. REMOVE BATTERY AND TRAY





5. DISCONNECT COOLING FAN INLET PIPE FROM FAN SHROUD
Remove the 2 bolts, brackets and bushings, and disconnect the inlet pipe.





6. DISCONNECT COOLING FAN RESERVOIR TANK FROM FAN SHROUD
a) Disconnect the suction hose from the clamp on the fan shroud.
b) Remove the 3 bolts, and disconnect the reservoir tank.





7. DISCONNECT ECT SENSOR CONNECTOR (FOR COOLING FAN)
a) Disconnect the ECT sensor connector.
b) Disconnect the wire clamp from the fan shroud.
8. REMOVE RADIATOR ASSEMBLY
a) Remove the 2 bolts, screw and upper radiator support. Remove the 2 upper radiator supports.
b) Slightly lift the radiator, and disconnect the 2 oil cooler hoses (for cooling fan) from the hose clamp on the radiator fan shroud.
c) Remove the radiator assembly.
d) Remove the 2 lower radiator supports from the radiator.
9. REMOVE FAN SHROUD FROM RADIATOR
Remove the 4 bolts and fan shroud.

DISASSEMBLY
1. REMOVE RADIATOR CAP





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 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.





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 upper tank.
b) Remove the O-ring.
7. REMOVE OIL COOLER FROM LOWER TANK





a) Remove the bolt.
b) Remove the 2 inlet sub assembly.





c) Remove the 2 nuts and 2 plate washers.
d) 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.)
d) Install the 2 inlet sub assembly.
e) Install the bolt.





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": 8.4 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 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 (H) 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 RADIATOR CAP

INSTALLATION





1. INSTALL FAN SHROUD TO RADIATOR
Install the fan shroud with the 4 bolts.
Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)





2. INSTALL RADIATOR ASSEMBLY
a) Install the 2 lower radiator supports to the radiator.
b) Place the radiator assembly on the body bracket.
c) Slightly lift the radiator, and connect the 2 oil cooler hoses (for cooling fan) to the hose clamp on the radiator fan shroud.
d) Install the upper radiator support with the screw and 2 bolts.
e) Install the 2 upper radiator supports.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.) for bolt





3. CONNECT ECT SENSOR CONNECTOR (FOR COOLING FAN)
a) Connect the ECT sensor connector.
b) Install the wire clamp to the fan shroud.





4. INSTALL COOLING FAN RESERVOIR TANK TO FAN SHROUD
a) Install the reservoir tank with the 3 bolts.
Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)
b) Install the suction hose to the clamp on the fan shroud.





5. INSTALL COOLING FAN INLET PIPE TO FAN SHROUD
Install the inlet pipe with the 2 bushings, brackets and bolts.
Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)
6. INSTALL BATTERY AND TRAY
7. CONNECT HOSES





a) Connect the upper radiator hose to the radiator.
b) Connect the radiator reservoir hose.





c) Connect the lower radiator hose to the radiator.
d) Connect the 2 oil cooler hose (for transmission) to the radiator.





e) Connect the pressure hose to the hydraulic motor with a new gasket and union bolt.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
f) Connect the return hose to the hydraulic motor.
8. FILL WITH ENGINE COOLANT
9. FILL WITH COOLING FAN FLUID
10. START ENGINE AND CHECK FOR LEAKS
11. RECHECK ENGINE COOLANT LEVEL
12. CHECK TRANSMISSION FLUID LEVEL
13. INSTALL ENGINE UNDER COVERS