RADIATOR REASSEMBLY


  1. INSPECT LOCK PLATE FOR DAMAGE


    1. B007V9ME02

      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. B007WFBE01

      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. B007Q7ME01

      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. B007RR8E01

      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. B007S7QE01

      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


      • B007U22

        Do not press the protruding areas around the ports.

      • B007RBY

        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. B007VFRE01

      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. B007OXR

      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. B007QC6

      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. B007RYZ

      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.