Overhaul

RADIATOR

COMPONENTS:

DISASSEMBLY

1. REMOVE SIDE SUPPORT
a. Remove the 4 nuts and 2 brackets.
b. Remove the 8 nuts and 2 side supports.
2. REMOVE DRAIN PLUG
a. Remove the drain plug.
b. Remove the O-ring.
3. UNCAULK LOCK PLATE

a. Install the claw to part A of the overhaul handle as shown in the illustration.
SST 09230-01010 (09231-01010, 09231-01030)
b. While squeezing the handle, adjust the stopper bolt so that dimension B is as specified.
Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 inch)

c. Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01030)

4. REMOVE TANK AND O-ring.
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.

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 NEW O-RING AND TANK

a. Check that there are no foreign objects in the lock plate groove, and install a new O-ring. Make sure the O-ring is not twisted.

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

b. Install the tank without damaging the O-ring.

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

d. Install the punch assembly to part A of the overhaul handle as shown in the illustration.
SST 09230-01010 (09231-01010, 09231-01020)
e. While gripping the handle, adjust the stopper bolt so that dimension B is as specified.
Dimension B: 8.4 mm (0.331 inch)
2. 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 squeezing the handle until stopped by the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01020)

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

^ Do not use SST to press the areas indicated by the circle marks 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 m (0.346 inch)
If the height is not within the specified height, readjust the stopper bolt of the handle and caulk the lock plate again.
3. INSTALL DRAIN PLUG
a. Install a new O-ring to the drain plug.
b. Install the drain plug.
4. 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: On radiators with resin tanks, there is clearance between the tank and lock plate where a small amount of air will remain. This air is released when the radiator is submerged in water, giving the appearance of an air leak. Before performing the water leak test, first shake the radiator in the water until all air bubbles are released.

5. INSTALL SIDE SUPPORT
a. Install the 2 side supports with the 8 nuts.
Torque: 12.7 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install the 2 brackets with the 4 nuts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)