Overhaul

OVERHAUL
1. REMOVE PACKING
2. REMOVE RADIATOR CAP SUB-ASSEMBLY
3. REMOVE DRAIN PLUG
a. Remove the drain plug.
b. Remove the O-ring.





4. ASSEMBLE SST
SST 09230-01010
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 in the illustration is within the specified range.
Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 inch)

NOTICE: If this adjustment is not performed, the claw will be damaged.





5. UNCAULK LOCK PLATE
Use SST to release the caulking.
1. Set the tip of SST to the look plate.
2. Grip the handle of SST until the stopper bolt contacts the handle to release the caulking.
SST 09230-01010 (09231-01010, 09231-01030)





6. REMOVE RADIATOR TANK UPPER AND TANK LOWER
a. Lightly tap the radiator bracket (or radiator hose inlet or outlet) with a plastic hammer and remove the tank.
b. Remove the O-ring.





7. REMOVE OIL COOLER ASSEMBLY
a. Remove the 2 inlets.
b. Remove the 2 nuts, 2 plate washers and oil cooler.
c. Remove the 2 O-rings from the oil cooler.





8. INSTALL OIL COOLER ASSEMBLY
a. Install 2 new O-rings to the oil cooler.
b. Install the oil cooler to the lower tank with the 2 plate washers and 2 nuts.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
c. Install the 2 inlets.
Torque: 14.7 Nm (150 kgf-cm, 11 ft. lbs.)





9. INSPECT LOCK PLATE FOR DAMAGE
Inspect the lock plate for damage.

HINT:
^ If the sides of the lock plate groove are deformed, reassembling the tank will be impossible. Correct any deformations with pliers.
^ Water leakage will occur if the bottom of the lock plate groove is damaged or dented. Repair or replace if necessary.

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





10. INSTALL RADIATOR TANK UPPER AND TANK LOWER
a. Check that the lock plate groove is free from foreign objects.
If necessary, clean the lock plate groove by lightly rubbing it with sandpaper.

NOTICE: Do not scratch the lock plate groove.

b. Install a new O-ring.
c. Check that the O-ring is not twisted.





d. Install the tank without damaging the O-ring.
e. Tap the lock plate with a plastic hammer. Be careful not to make a gap between the lock plate and the tank.





11. 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 in the illustration is within the specified range.
Dimension B: 8.4 mm (0.33 inch)





12. 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 gripping the handle until stopped by the stopper bolt.
SST 09230-01010





NOTICE:
^ Do not press the areas protruding around the ports (1), flange (2) and brackets (3).





^ Do not press the circled areas in the illustration. Use pliers and be careful not to damage the core plates.





b. Check the lock plate height (H) after completing the caulking.
Plate height (H): 8.8 mm (0.346 inch)
If the height is not as specified, adjust the stopper bolt of the handle and caulk the lock plate again.
13. INSTALL DRAIN PLUG
a. Install a new O-ring to the drain plug.
b. Install the drain plug.





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





d. Inspect for leaks.

HINT: For radiators with resin tanks, perform the water leak test after submerging the radiator in the water and shaking it until all the bubbles are released. The bubbles are the result of air trapped in the clearance between the tank and lock plate.

15. INSTALL RADIATOR CAP SUB-ASSEMBLY
16. INSTALL PACKING