1 of 12 9/25/2015 9:29 PM - JustAnswer · 1 of 12 9/25/2015 9:29 PM. REMOVAL ... UNCAULK LOCK PLATES ... Use pliers or similar object and be careful not to damage the core plates

Radiator |Service and Repair, Procedures: Removal and Installation http://repair.alldata.com/alldata/article/display.action?componentId=81&...

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REMOVAL


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1. DRAIN ENGINE COOLANT 2. REMOVE RADIATOR GRILLE Remove the 4 screws, 2 clips and radiator grille.

3. REMOVE FRONT END PANEL Remove the 4 screws and front end panel.

4. DISCONNECT HOOD LOCK a. Remove the 3 bolts, and disconnect the hood lock. b. Disconnect the wire from the clamp. 5. DISCONNECT UPPER RADIATOR HOSE


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6. REMOVE UPPER RADIATOR SUPPORT Remove the 5 bolts and radiator support. 7. REMOVE LH ENGINE UNDER COVER 8. REMOVE RADIATOR RESERVOIR 9. REMOVE NO. 1 AND NO. 2 COOLING FANS 10. A/T: DISCONNECT OIL 2 HOSES Disconnect the 2 oil cooler hoses from the radiator. 11. DISCONNECT ECT SWITCH CONNECTOR 12. DISCONNECT LOWER RADIATOR HOSE 13. REMOVE RADIATOR 14. REMOVE UPPER AND LOWER RADIATOR SUPPORTS FROM RADIATOR

DISASSEMBLY 1. REMOVE DRAIN PLUG a. Remove the drain plug. b. Remove the O-ring.

2. 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" is as shown in the illustration. Dimension "B": 0.2 - 0.3 mm (0.008 - 0.012 inch)

NOTICE: If this adjustment is not done the claw may be damaged.

3. UNCAULK LOCK PLATES Using SST to release the caulking, squeeze the handle until stopped by the stopper bolts.


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SST 09230-01010

4. REMOVE TANKS AND O-RINGS 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: REMOVE OIL COOLER PIPES FROM LOWER TANK a. Loosen the 2 nuts, and remove the 2 pipes. b. Remove the 2 nuts. c. Remove the 2 O-rings from the oil cooler.

REASSEMBLY

1. A/T: INSTALL OIL COOLER PIPES TO LOWER TANK a. Install 2 new O-rings to the oil cooler. b. Install the 2 nuts. Torque: 12 Nm (120 kgf-cm, 10 ft. lbs.)


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c. Install the LH cooler pipe in the direction indicated in the illustration. Torque: 14.7 Nm (150 kgf-cm, 11 ft. lbs.) d. Install the RH cooler pipe. Torque: 14.7 Nm (150 kgf-cm, 11 ft. lbs.)

2. 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 anydeformation 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.

3. 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 sandpaper without scratching it.

b. Install the tank without damaging the O-ring.


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c. Tap the lock prate with a soft-faced hammer so that there is no gap between it and the tank.

4. 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 "B": 8.4 mm (0.331 inch)


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5. 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 lockplate by squeezing the handle until touch the stopper bolt. SST 09230-01010

HINT: ^ Do not stake the areas protruding around the pipes, brackets or tank ribs.


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^ The points shown in the illustration cannot be staked with SST. Use pliers or similar object and be careful not to damage the coreplates.

b. Check the lock plate height (H) after completing the caulking. Plate height (H): 8.45 - 8.85 mm (0.3327 - 0.3484 inch) If not within the specified height, adjust the stopper bolt of the handle again and caulk again. 6. INSTALL DRAIN PLUG a. Install a new O-ring to the drain plug. b. Install the drain plug.

7. INSPECT FOR WATER LEAKS a. Tighten the drain plug. b. Plug the inlet and outlet pipes of the radiator with SST. SST 0923-01010


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c. Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi) d. Submerge the radiator in water.

e. 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 theradiator around in the water until all bubbles disappear.

INSTALLATION 1. INSTALL UPPER AND LOWER RADIATOR SUPPORTS TO RADIATOR 2. INSTALL RADIATOR 3. CONNECT LOWER RADIATOR HOSE 4. A/T: CONNECT 2 HOSES Connect the 2 oil cooler hoses to the radiator. 5. CONNECT ECT SWITCH CONNECTOR 6. INSTALL NO. 1 AND NO. 2 COOLING FANS 7. INSTALL RADIATOR RESERVOIR 8. INSTALL RH ENGINE UNDER COVER

9. INSTALL UPPER RADIATOR SUPPORT Install the radiator upper support with the 5 bolts.


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10. CONNECT UPPER RADIATOR HOSE 11. CONNECT HOOD LOCK a. Install the hood lock with the 3 bolts. b. Install the wire from the clamps.

12. INSTALL FRONT END PANEL Install the front end panel with the 4 screws.

13. INSTALL RADIATOR GRILLE Install the radiator grille with the 4 screws and 2 clips. 14. FILL WITH ENGINE COOLANT 15. START ENGINE AND CHECK FOR COOLANT LEAKS


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1 of 12 9/25/2015 9:29 PM - JustAnswer · 1 of 12 9/25/2015 9:29 PM. REMOVAL ... UNCAULK LOCK PLATES ... Use pliers or similar object and be careful not to damage the core plates