Overhaul

RADIATOR (ALUMINUM TYPE)

CO-45 Component:

Disassembly and Assembly

PREPARATION





1. Attach spacer to tip of radiator plate pliers A (SST).
Spacer specification: 18 mm (0.71 in) wide x 8.5 mm (0.335 in) long x 1.5 mm (0.059 in) thick.
2. Check that when radiator plate pliers A [SST: KV99103510 ( - )] are closed dimension H" is approx. 7.6 mm (0.299 in).
3. Adjust dimension H" with spacer, if necessary.

DISASSEMBLY





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

CAUTION: Never disassemble lower tank and A/T fluid cooler.

NOTE: Regard lower tank and A/T fluid cooler as an assembly.





^ Grip the crimped edge and bend it upwards so that radiator plate pliers B [SST: KV99103520 ( - )] slips off.

CAUTION: Never bend excessively.





^ In areas where radiator plate pliers B [SST: KV99103520 ( - )] cannot be used, use flat-blade screwdriver to bend the edge up.

CAUTION: Be careful not to damage tank.

2. Remove sealing rubber.





3. Check the edge stands straight up.

ASSEMBLY





1. Clean contact portion of tank.





2. Install new sealing rubber while pushing it with fingers.

CAUTION: Be careful not to twist sealing rubber.





3. Caulk tank in numerical order as shown in the figure with radiator plate pliers A (SST).








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





4. Check that the rim is completely crimped down.
Standard height "H": 8.0 - 8.4 mm (0.315 - 0.331 in)
5. Check that there is no leakage. Refer to "INSPECTION".

INSPECTION





1. Apply pressure with radiator cap tester adapter (commercial service tool) and radiator cap tester (commercial service tool).
^ provide used radiator and connect it to tested radiator using radiator hoses as shown in the figure.

NOTE: The used radiator should be tested beforehand to confirm it has no leakage. If used one is not available, it is possible to use new service part as a radiator testing tool.

Testing pressure: 157 kPa (1.6 kg/cm2, 23 psi)

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

CAUTION: Attach hose to A/T fluid cooler to seal its inlet and outlet.





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