Overhaul

RADIATOR ASSEMBLY
OVERHAUL
1. REMOVE RADIATOR DRAIN COCK PLUG
a. Remove the drain cock plug.
b. Remove the O-ring from the drain cock plug.





2. ASSEMBLE SST
SST 09230-01010 (09231-01010, 09231-01030)
a. Install the claw to the overhaul handle by 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" is as shown in the illustration.
Dimension "B": 0.2 to 0.3 mm (0.008 to 0.012 inch)

NOTICE: If the stopper bolt is not adjusted, the claw may be damaged.





3. UNCAULK CORE PLATE
a. Using SST to release the core plate, grip the handle until stopped by the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01030)





4. REMOVE RADIATOR TANK UPPER
a. Lightly tap the bracket of the radiator tank (or radiator tank pipe) with a soft-faced hammer, then remove the radiator tank.
b. Remove the O-ring.
5. REMOVE RADIATOR TANK LOWER

HINT: Perform the same procedures as the radiator tank upper.





6. REMOVE INLET NO.1
a. Remove the bolt.
b. Remove the nut and inlet No. 1.





7. REMOVE INLET NO.2
a. Remove the nut and inlet No. 2.





8. REMOVE ATM OIL COOLER
a. Remove the 2 nuts and 2 washers, then remove the oil cooler from the radiator tank.
b. Remove the 2 O-rings from the oil cooler.





9. INSPECT RADIATOR CORE SUB-ASSEMBLY
Check the core plate for damage.

HINT:
^ If the sides of the core plate groove are deformed, it will be impossible to reassemble the radiator tank. Therefore, first correct any deformation with pliers or a similar tool.
^ Water leakage will result if the bottom of the core plate groove is damaged or dented. Repair or replace if necessary.

NOTICE: The radiator can only be recaulked 2 times. After being recaulked 2 times, the radiator core must be replaced.





10. INSTALL ATM OIL COOLER
a. Install the 2 new O-rings to the oil cooler.
b. Install the oil cooler to the radiator tank.
c. Install the 2 nuts and 2 washers.
Torque: 8.3 Nm (85 kgf-cm, 74 inch lbs.)
11. INSTALL INLET NO.2
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
12. INSTALL INLET NO.1
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
13. INSTALL RADIATOR TANK UPPER





a. After checking that there are no foreign objects in the core plate groove, install a new O-ring without twisting it.

HINT: When cleaning the core plate groove, lightly rub it with sandpaper without scratching it.





b. Install the radiator tank without damaging the O-ring.
c. Tap the core plate with a soft-faced hammer so that there is no gap between the core plate and radiator tank.
14. INSTALL RADIATOR TANK LOWER HINT Perform the same procedures as the radiator tank upper.





15. ASSEMBLE SST
SST 09230-01010 (09231-01010, 09231-01020)
a. Install the punch assembly to the overhaul handle by 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" is as shown in the illustration.
Dimension "B": 8.4 mm (0.341 inch)
16. CAULK CORE PLATE





a. Lightly press SST against the core plate in the order shown in the illustration. After repeating this a few times, fully caulk the core plate by gripping the handle until stopped by the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01020)

HINT:





^ Do not tap the areas protruding around the pipes, brackets or tank ribs.





^ The points shown in the illustration and oil cooler near here cannot be tapped with the SST Use pliers or a similar tool and be careful not to damage the core plate.





b. Check the core plate height (H) after completing the caulking.
Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 inch)
If the height is not as specified, adjust the stopper bolt of the handle again, then caulk again.
17. INSTALL RADIATOR DRAIN COCK PLUG
a. Install a new O-ring to the drain cock plug.
b. Install the drain cock plug.