RADIATOR REASSEMBLY


  1. INSTALL RADIATOR TANK UPPER AND TANK LOWER


    1. A0137QYE02

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

  2. ASSEMBLE SST

    SST
    09230-01010
    09231-14010

    1. A0136FXE02

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

    2. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration.

      Dimension B
      8.4 mm (0.331 in.)

  3. CAULK LOCK PLATE

    SST
    09230-01010

    1. A0136SRE03

      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 gripping the handle until it is stopped by the stopper bolt.

    2. A0138Z1E02

      Do not tap the areas protruding around the ports (1), claws (2) and grooves (3).

    3. A01369W

      The points shown in the illustration cannot be tapped with SST. Use pliers and be careful not to damage the core plates.

    4. A0137L9E01

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

  4. INSPECT FOR WATER LEAKS

    SST
    09230-01010

    1. A0137CTE02

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

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

      Test pressure
      177 kPa (1.8 kgf*cm2, 26 psi)

      Note

      Do not put more than 177 kpa (1.8 kgf*cm2, 26 psi) to radiator.

    3. Submerge the radiator in water.

    4. A0138J8E02

      Inspect for leaks.

      Tech Tips

      On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Before doing the water leak test, first shake the radiator in the water until air bubbles disappear.