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 that 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


    1. A0136FXE02

      Assemble the SST.

      SST
      09230-01010
      09231-14010

      1. Attach the punch assembly to the overhaul handle at the hole on 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


    1. A0136V0E02

      Lightly press SST against the lock plate 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.

      SST
      09230-01010
    2. A0136ECE01

      The lock plate around areas (1), (2), and (3) in the illustration should not be tapped with SST.

    3. A0138UU

      Be sure to use pliers to tap these points as shown in the illustration.

      Note

      Be careful not to damage the core plates.

    4. A0138HAE01

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

      Plate height (H)
      7.4 to 7.8 mm (0.2959 to 0.3119 in.)

      If not within the specified height, adjust the stopper bolt of the handle again and caulk again.

  4. INSPECT FOR WATER LEAKS


    1. A0137CTE02

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

      SST
      09230-01010

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

      Test pressure
      177 kPa (1.77 bar, 26 psi)

      Note

      Do not apply more than 177 kpa (1.77 bar, 26 psi) to the 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.