RADIATOR REASSEMBLY

INSTALL RADIATOR TANK UPPER

1. 

   Text in Illustration

   *1	Stopper Bolt
   *2	Overhaul Handle
   *3	Punch Assembly
   *a	Dimension B
   *b	Part A

   Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration.

   SST

   09230-01010   ( 09231-01010, 09231-01020 )

   09231-14010

2. While gripping the handle, adjust the stopper bolt so that dimension B is as specified below.

   Dimension B
   7.4 to 7.8 mm (0.29 to 0.30 in.)

3. 

   Text in Illustration

   *1	O-ring
   *a	Correct
   *b	Incorrect

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

   Note

   When cleaning the core plate groove, lightly rub it with sandpaper without scratching it.

4. 

   Text in Illustration

   *1	Tank
   *2	Core Plate
   *a	Correct
   *b	Incorrect
   *c	Gap

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

5. 

   Text in Illustration

   *1	Core Plate
   *a	Press Against

   Lightly press the crimping tool against the core plate in the order shown in the illustration. After repeating this a few times, fully crimp the core plate by squeezing the handle until stopped by the stopper bolt.

   Note

   
   

   • For positions where the crimping tool is not usable, crimp using pliers.

   • Crimp according to the order shown in the illustration.

6. 

   Text in Illustration

   *1	Tank
   *2	Core Plate
   *3	O-ring
   *a	Dimension D

   Check dimension D after crimping.

   Standard dimension
   7.4 to 7.8 mm (0.29 to 0.30 in.)

7. In the event that dimension D does not fall within the standard limit, adjust the stopper bolt on the handle once again and recrimp.

   Note

   Check the dimensions at both ends of the core plate as well as around the central portion where the crimping has not been performed (under the pipe, etc.).

8. Others:

   Mark for the first repair and the second repair in a highly visible place on the upper tank.

   Note

   The radiator can only be recrimped twice. After the second time, the radiator core must be replaced.

INSTALL RADIATOR TANK LOWER

INSPECT FOR COOLANT LEAK

1. 

   Text in Illustration

   *1	Handle
   *2	Washer (Small)
   *3	Washer (Large)
   *4	Plug
   *5	Nut

   Assemble the plug handle as shown in the illustration, and tighten the nut until the washer, the plug and the handle are in light contact with each other.

2. 

   Text in Illustration

   *1	Tank
   *2	Core Plate
   *3	O-ring

   Using SST, plug the inlet and outlet pipes of the radiator.

   SST

   09230-01010   ( 09231-00030, 09231-00050 )

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

   Test pressure
   118 kPa (1.2 kgf/cm2, 17 psi)

   Tech Tips

   On radiators with resin tanks, there is a clearance between the core plate and tank plate where a minute amount of air will remain, giving the appearance of air leaks when the radiator is submerged in water. Therefore, before performing the water leak test, first swirl the radiator around in the water until all air bubbles disappear.

   

INSTALL RADIATOR SIDE PLATE