Radiator: Service and Repair

REMOVAL AND INSTALLATION
1. Remove under cover.
2. Drain coolant from radiator.
3. Disconnect radiator upper and lower hoses.
4. Remove radiator shroud.
5. Remove A/T oil cooler hoses. (A/T models only)
6. Disconnect reservoir tank hose.
7. Remove radiator mounting bracket.
8. Remove radiator.
9. After repairing or replacing radiator, install any part removed in reverse order of removal.

RADIATOR (ALUMINUM TYPE)





Preparation





1. Attach the spacer to the tip of the radiator plate pliers A. Spacer specification: 1.5 mm (0.059 inch) thick x 18 mm (0.71 inch) wide x 8.5 mm (0.335 inch) long.
2. Make sure that when radiator plate pliers A are closed dimension "H" is approximately 7.6 mm (0.299 inch).
3. Adjust dimension H., with the spacer, if necessary.

Disassembly





1. Remove tank with Tool.





- Grip the crimped edge and bend it upwards so that Tool slips off.
Do not bend excessively.





- In areas where Tool cannot be used, use a screwdriver to bend the edge up.
Be careful not to damage tank.





2. Make sure the edge stands straight up.
3. Remove oil cooler from tank. (A/T models only)

Assembly





1. Install oil cooler. (A/T models only)
Pay attention to direction of conical washer.





2. Clean contact portion of tank.





3. Install sealing rubber.
Push it in with fingers.
Be careful not to twist sealing rubber.








4. Caulk tank in specified sequence with Tool.





- Use pliers in the locations where Tool cannot be used.





5. Make sure that the rim is completely crimped down.

Standard height "H": 8.0 - 8.4 mm (0.315 - 0.331 inch)

6. Confirm that there is no leakage.

Inspection





Apply pressure with Tool.

Specified pressure value: 157 kPa (1.6 kg/cm2, 23 psi)

WARNING: To prevent the risk of the hose coming undone while under pressure, securely fasten it down with a hose clamp. Attach a hose to the oil cooler as well. (A/T models only)