RADIATOR (w/ EGR Cooler) REASSEMBLY


  1. INSPECT LOCK PLATE FOR DAMAGE


    1. A01DYN2E02

      Inspect 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 LOWER


    1. A01E19IE01

      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. A01E30AE01

      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. A01E2XYE01

      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. A01DWVOE01

      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


      • A01DVABE02

        Do not press the protruding areas around the ports (1) and bracket (2).

      • A01DVQ5E01

        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. A01E1ALE01

      Check the lock plate height H after completing the caulking.

      Standard plate height H
      8.8 mm (0.346 in.)

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

  5. INSTALL RADIATOR DRAIN COCK PLUG


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

    2. Install the drain plug.

  6. INSPECT FOR WATER LEAKS


    1. A01DW6HE01

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

      SST
      09230-01010   ( 09231-00030, 09231-00060 )

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

      Standard test pressure
      177 kPa (1.8 kgf/cm2, 26 psi)

    3. Submerge the radiator in water.

    4. A01DY9AE02

      Inspect for leaks.

      Tech Tips

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

  7. INSTALL RADIATOR BRACKET SUB-ASSEMBLY


    1. A01DZ80E02

      Install the 2 brackets with the 4 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }