RADIATOR REASSEMBLY


  1. INSPECT LOCK PLATE FOR DAMAGE


    1. A003DZXE02

      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 RADIATOR TANK UPPER AND TANK LOWER


    1. A003H4XE01

      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. A003HQIE01

      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. A003BTXE01

      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.)

  4. CAULK LOCK PLATE


    1. A003BWSE01

      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


      • A003B1K

        Do not press the protruding areas around the ports.

      • A003ECS

        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. A003GRFE01

      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. A003C06

      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 NO. 1 RADIATOR LOWER TANK PIPE


    1. A003H9D

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

    2. Install the No. 1 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. A003D1Z

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

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