Disassembly and Reassembly
Part 1 Of 3:
Part 2 Of 3:
Part 3 Of 3:
DISASSEMBLY
1. REMOVE DRAIN PLUG
a. Remove the drain plug.
b. Remove the O-ring.
2. DENSO Made: ASSEMBLE SST
SST 09230-01010
a. Install the claw to the overhaul handle, inserting it in the hole in part "A" as shown in the diagram.
b. While gripping the handle, adjust the stopper bolts so that dimension "B" shown in the diagram is 0.2 - 0.3 mm (0.008 - 0.012 inch).
NOTICE: If this adjustment is not done the claw may be damaged.
3. DENSO Made: UNCAULK LOCK PLATES
Using SST to release the caulking, squeeze the handle until stopped by the stopper bolts.
SST 09230-01010
4. DENSO Made: REMOVE TANKS AND O-RING
Lightly tap the bracket of the radiator (or radiator inlet or outlet) with a soft-faced hammer, and remove the tank and the O-ring.
5. A/T (DENSO Made): REMOVE OIL COOLER FROM LOWER TANK
a. Loosen the nut, and remove the cooler pipe.
b. Remove the 2 nuts and 2 plate washers.
c. Remove the oil cooler and 2 O-rings.
INSPECTION
DENSO Made: INSPECT LOCK PLATE FOR DAMAGE
HINT:
^ If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible.
^ Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the bottom of the lock plate groove is damaged.
NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.
REASSEMBLY
1. A/T (DENSO Made): INSTALL OIL COOLER TO LOWER TANK
a. Clean the O-ring contact surface of the lower tank and oil cooler.
b. Install 2 new O-rings to the oil cooler.
c. Install the oil cooler to the lower tank.
d. Install the 2 plate washers and 2 nuts.
Torque: 8.34 Nm (85 kgf-cm, 74 inch lbs.)
e. Install the cooler pipe in the direction indicated as shown in the illustration.
Torque: 14.7 Nm (150 kgf-cm, 11 ft. lbs.)
2. DENSO Made: INSTALL NEW O-RINGS AND TANKS
a. After checking that there are no foreign objects in the lock plate groove, install the new O-ring without twisting it.
HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.
b. Install the tank without damaging the O-ring.
c. Tap the lock prate with a soft-faced hammer so that there is no gap between it and the tank.
3. DENSO Made: ASSEMBLE SST
SST 09230-01010, 09231-14010
a. Install the punch assembly to the overhaul handle, inserting it in the hole in part "A" as shown in the illustration.
b. While gripping the handle, adjust the stopper bolt so that dimension "B" is as shown in the illustration.
Dimension: 8.4 mm (0.331 inch)
4. DENSO Made: CAULK LOCK PLATE
a. 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 stopped plate.
SST 09230-01010
HINT:
^ Do not stake the areas protruding around the pipes, brackets or tank rids.
^ The points shown in the illustration and oil cooler near here (A/T) cannot be staked with SST. Use wrap vinyl tape around the tip of a pair or similar object and be careful not to damage the core plates.
b. Check the lock plate height (H) after completing the caulking.
Plate height: 7.40 - 7.80 mm (0.2913 - 0.3071 inch)
If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
5. INSTALL DRAIN PLUG
a. Install a new O-ring to the drain plug.
b. Install the drain plug.
6. INSPECT FOR WATER LEAKS
a. Tighten the drain plug.
b. Install the engine coolant reservoir.
c. Plug the inlet and outlet pipes of the radiator with SST.
SST 09230-01010
d. Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi)
Submerge the radiator in water.
f. Inspect for leaks.
HINT: 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. therefore, before doing the water leak test, first swish the radiator around in the water until all bubbles disappear.