RADIATOR REASSEMBLY


  1. INSPECT LOCK PLATE FOR DAMAGE


    1. A01BGE7E05
      Text in Illustration
      *1 Core
      *a Lock Plate

      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 as necessary.

      Note

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

  2. INSTALL UPPER RADIATOR TANK


    1. A01BDZ4E01
      Text in Illustration
      *1 O-Ring
      *a CORRECT
      *b INCORRECT
      *c Normal
      *d Twisted

      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. A01BDI8E03
      Text in Illustration
      *1 Tank
      *a Lock Plate
      *b CORRECT
      *c INCORRECT

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

  3. INSTALL LOWER RADIATOR TANK

    Tech Tips

    Use the same procedure described for the upper radiator tank.

  4. ASSEMBLE SST


    1. A01BAWQE08
      Text in Illustration
      *a Part A
      *b Stopper Bolt
      *c Dimension B

      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 squeezing the handle, adjust the stopper bolt so that dimension B is as specified below.

      Dimension B
      8.4 mm (0.331 in.)

  5. CAULK LOCK PLATE


    1. A01BB6ME02
      Text in Illustration
      *a Stopper Bolt
      *b Tank
      *c Lock Plate

      Lightly press SST and pliers against the lock plate in the order shown in the illustration. Repeat this step a few times, and then 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. A01BE7KE02
      Text in Illustration
      *a Lock Plate Height

      Check the lock plate height after completing the caulking.

      Standard plate height
      8.6 mm (0.333 in.)

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

  6. INSTALL LOWER NO. 2 RADIATOR TANK PIPE


    1. Install the lower No. 2 radiator tank pipe, and slide the hose clamp to secure the pipe.

    2. Connect the lower No. 2 radiator tank pipe to the radiator assembly with the bolt.

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

  7. INSTALL LOWER NO. 1 RADIATOR TANK PIPE


    1. Install a new O-ring to the lower No. 1 radiator tank pipe.

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

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

  8. INSTALL UPPER RADIATOR TANK PIPE


    1. Install a new O-ring to the radiator upper tank pipe.

    2. Install the upper radiator tank pipe with the 3 bolts.

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

  9. INSTALL RADIATOR DRAIN COCK PLUG


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

    2. Install the drain cock plug.