Disassembly and Assembly

RADIATOR (ALUMINUM TYPE)





Disassembly and Assembly

PREPARATION





1. Attach the spacer to the tip of radiator plate pliers A (SST). Spacer specification: 1.5 mm (0.059 inch) thick x 18 mm (0.71 inch) wide x 8.5 mm (0.335 inch) long.
2. Make sure that when radiator plate pliers A (SST) are closed dimension "H" is approximately 7.6 mm (0.299 inch).
3. Adjust dimension "H" with the spacer, if necessary.

DISASSEMBLY





1. Remove upper or lower tanks with radiator plate pliers B (SST).





^ Grip the crimped edge and bend it upwards so that radiator plate pliers B [SST: KV99103520 (-)] slips off.
Do not bend excessively.





^ In areas where radiator plate pliers B [SST: KV99103520 (-)] cannot be used, use a screwdriver to bend the edge up.
Be careful not to damage tank.

2. Remove sealing rubber.





3. Make sure the edge stands straight up.
4. Remove oil cooler from tank.

ASSEMBLY





1. Install oil cooler.
Pay attention to direction of conical washer.





2. Clean contact portion of tank.





3. Install sealing rubber.
Push it in with fingers.
Be careful not to twist sealing rubber.








4. Caulk tank in specified sequence with radiator plate pliers A (SST).





^ Use pliers in the locations where plate pliers A [SST: KV99103510 (-)] cannot be used.





5. Make sure that the rim is completely crimped down.
Standard height "H": 8.0 - 8.4 mm (0.315 - 0.331 inch)
6. Confirm that there is no leakage.

INSPECTION





1. Apply pressure with radiator cap tester adapter (SST) and radiator cap tester (commercial service tool).
Testing pressure: 157 kPa (1.6 kg/cm2, 23 psi)

WARNING: To prevent the risk of the hose coming undone while under pressure, securely fasten it down with a hose clamp.

CAUTION: Attach a hose to the oil cooler to seal its inlet and outlet.





2. Check for leakage by soaking radiator in water container with the testing pressure applied.