Radiator: Service and Repair

DISASSEMBLY AND REASSEMBLY





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 model only)

REASSEMBLY





1. Install oil cooler. (A/T model 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. Crimp 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.
Refer to Inspection.

INSPECTION





1. 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 model only)





2. Check for leakage.