Overhaul

RADIATOR

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

DISASSEMBLY

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

4. UNCAULK LOCK PLATE

(a) Install the claw to part A of the overhaul handle as shown in the illustration.
SST 09230-01010
(b) While squeezing the handle, adjust the stopper bolt so that dimension B is as specified below.
Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 in.)

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

(c) Using SST, release the caulking.
(1) Set the tip of SST to the lock 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)

5. REMOVE RADIATOR TANK
(a) Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a plastic-faced hammer and remove the tank.
(b) Remove the O-ring.

6. REMOVE OIL COOLER
(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.

INSPECTION

1. INSPECT LOCK PLATE FOR DAMAGE
(a) Inspect the lock plate for damage.
If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Correct any deformations with pliers.
Water will leak if the bottom of the lock plate groove is damaged or dented. Repair or replace it if necessary.

NOTICE: The radiator can only be recaulked twice. After the second time, the radiator core must be replaced.

REASSEMBLY

1. INSTALL OIL COOLER
(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 N*m (86 kgf*cm, 74 in.*lbf)
(c) Install the 2 inlets.
Torque: 14.7 N*m (150 kgf*cm, 11 ft.*lbf)

2. INSTALL RADIATOR TANK
(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.

(e) Tap the lock plate with a plastic-faced hammer so that there is no gap between the lock plate and the tank.

3. CAULK LOCK PLATE

(a) Install the punch assembly to part A of the overhaul handle as shown in the illustration.
SST 09230-01010, 09231-14010
(b) While gripping the handle, adjust the stopper bolt so that dimension B is as specified below.
Dimension B: 8.4 mm (0.33 in.)

(c) 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, 09231-14010

NOTICE:
^ Do not press the protruding areas around the ports A, flange B and bracket C.

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

(d) Check the lock plate height H after completing the caulking.
Plate height H: 8.8 mm (0.346 in.)
If the height is not within the specified height, readjust the stopper bolt of the handle and caulk the lock plate again.

4. INSTALL RADIATOR DRAIN COCK PLUG
(a) Install a new O-ring to the drain plug.
(b) Install the drain plug.

5. INSPECT WATER LEAK

(a) Plug the inlet and out let 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 radiator with resin tanks, perform the water leak test after submerging the radiator in 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.

6. INSTALL RADIATOR CAP SUB-ASSEMBLY
7. INSTALL PACKING