Radiator ASSY: Overhaul

1. Remove the drain plug.
2. Remove the O-ring.

SST 09230-01010

1. Install the claw to the overhaul handle by inserting it in the hole in part A as shown in Fig 1.
2. While gripping the handle, adjust the stopper bolt so that dimension B in Fig 1 is within the specified range.

   Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 in.) 

Fig 1: Assemling SST

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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)

   Fig 2: Uncaulking Lock Plate

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1. Lightly tap the radiator bracket (or radiator hose inlet or outlet) with a plastic hammer and remove the tank.
2. Remove the O-ring.
   Fig 3: Removing Radiator Tank Upper & Lower

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1. Remove the 2 inlets.
2. Remove the 2 nuts, 2 plate washers and oil cooler.
3. Remove the 2 O-rings from the oil cooler.
   Fig 4: Removing Oil Cooler Assy

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1. Install 2 new O-rings to the oil cooler.
2. Install the oil cooler to the lower tank with the 2 plate washers and 2 nuts.

   Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf) 

3. Install the 2 inlets.

   Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf) 

   Fig 5: Installing Oil Cooler Assy

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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.

Fig 6: Inspecting Lock Plate For Damage

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1. Check that the lock plate groove is free from foreign objects.

   If necessary, clean the lock plate groove by lightly rubbing it with sandpaper.

   NOTE: Do not scratch the lock plate groove.
2. Install a new O-ring.
3. Check that the O-ring is not twisted.
   Fig 7: Checking O-Ring Is Not Twisted

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4. Install the tank without damaging the O-ring.
5. Tap the lock plate with a plastic hammer. Be careful not to make a gap between the lock plate and the tank.
   Fig 8: Tapping Lock Plate With Plastic Hammer

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SST 09230-01010, 09231-14010

1. Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in Fig 9.
2. While gripping the handle, adjust the stopper bolt so that dimension B in Fig 9 is within the specified range.

   Dimension B: 8.4 mm (0.33 in.) 

   Fig 9: Assembling SST

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1. Lightly press SST against the lock plate in the order shown in Fig 10. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper bolt.

   SST 09230-01010

   Fig 10: Pressing SST Against Lock Plate In Order

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   NOTE:

   • Do not press the areas protruding around the ports (1), flange (2) and brackets (3).
     Fig 11: Do Not Press Areas Protruding Around Ports, Flange & Brackets

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   • Do not press the circled areas in Fig 12. Use pliers and be careful not to damage the core plates.
     Fig 12: Do Not Press Circled Areas

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2. Check the lock plate height (H) after completing the caulking.

   Plate height (H): 8.8 mm (0.346 in.) 

If the height is not as specified, adjust the stopper bolt of the handle and caulk the lock plate again.

Fig 13: Checking Lock Plate Height

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1. Install a new O-ring to the drain plug.
2. Install the drain plug.

1. Plug the inlet and outlet pipes of the radiator with SST.

   SST 09230-01010

   Fig 14: Plugging Inlet & Outlet Pipes Of Radiator With SST

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2. Using a radiator cap tester, apply pressure to the radiator.

   Test pressure: 177 kPa (1.8 kgf/cm ²  , 26 psi) 

3. Submerge the radiator in water.
4. 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.

Fig 15: Inspecting For Leaks

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