RADIATOR REASSEMBLY


  1. INSPECT LOCK PLATE FOR DAMAGE


    1. A01BGE7E02

      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.

      Note

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

  2. INSTALL RADIATOR TANK UPPER AND RADIATOR TANK LOWER


    1. A01BG3UE01

      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.

      Tech Tips

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

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

    3. A01BDI8E01

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

  3. ASSEMBLE SST


    1. A01BAWQE01

      Install the punch assembly to part A of the overhaul handle 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
      8.4 mm (0.331 in.)

  4. CAULK LOCK PLATE


    1. A01BB6ME01

      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 )
      09231-14010

      Note


      • A01BBQU

        Do not press the protruding areas around the ports.

      • A01BFV7

        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.

    2. A01BE7KE01

      Check the lock plate height H after completing the caulking.

      Standard plate height H
      8.45 mm (0.333 in.)

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

  5. INSTALL NO. 2 RADIATOR LOWER TANK PIPE


    1. A01BB5R

      Connect the No. 2 radiator lower tank pipe.

    2. Install the No. 2 radiator lower tank pipe with the bolt.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  6. INSTALL RADIATOR LOWER TANK PIPE


    1. A01BCJ7

      Install the 2 new O-rings to the 2 radiator lower tank pipes.

    2. Install the No. 1 radiator lower tank pipe with the 3 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    3. Install the No. 2 radiator lower tank pipe with the 3 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  7. INSTALL RADIATOR UPPER TANK PIPE


    1. A01BHDH

      Install the 2 new O-rings to the 2 radiator upper tank pipes.

    2. Install the 2 radiator upper tank pipes with the 6 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  8. INSTALL RADIATOR DRAIN COCK PLUG


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

    2. Install the drain cock plug.