Removal and Installation
Part 1 Of 2:
Part 2 Of 2:
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE ENGINE UNDER COVERS
3. REMOVE RADIATOR ASSEMBLY
a. Disconnect the electric cooling fan connector.
b. Disconnect the hone connector.
c. Disconnect the upper radiator hose.
d. Disconnect the lower radiator hose.
e. Disconnect the radiator reservoir hose.
f. A/T: Disconnect the 2 oil cooler hoses.
g. Remove the 2 clips and radiator cover.
h. Remove the 7 (w/o A/C) or 9 (w/ A/C) bolts and upper radiator supports.
i. Remove the radiator assembly.
j. Remove the 2 radiator support cushions and grommets.
4. REMOVE ELECTRIC COOLING FAN FROM RADIATOR
Remove the 3 bolts and cooling fan assembly.
DISASSEMBLY
1. REMOVE DRAIN PLUG
a. Remove the drain plug.
b. Remove the O-ring.
2. REMOVE WATER FILTER
a. Disconnect the No. 3 radiator hose from the radiator.
b. Remove the 2 bolts and water filter.
3. ASSEMBLE SPECIAL SERVICE TOOL (SST)
(SST) 09230-01010
a. Install the claw 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 bolts so that dimension "B" shown in the illustration is 0.2 - 0.3 mm (0.008 - 0.012 inch).
NOTICE: If this adjustment is not done the claw may be damaged.
4. UNCAULK LOCK PLATES
Using SST to release the caulking, squeeze the handle until stopped by the stopper bolts.
SST 09230-01010
5. 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.
6. A/T: REMOVE OIL COOLER FROM LOWER TANK
a. Remove the 2 nuts and 2 plate washers.
b. Remove the oil cooler and 2 O-rings.
INSPECTION
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: INSTALL OIL COOLER TO LOWER TANK
a. Install 2 new O-rings to the oil cooler.
b. Install the oil cooler to the lower tank.
c. Install the 2 plate washers and 2 nuts.
Torque: 8.34 Nm (85 kgf-cm, 74 inch lbs.)
2. 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. ASSEMBLE SPECIAL SERVICE TOOL (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. CAULK LOCK PLATE
a. Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, 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 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 WATER FILER
a. Install the water filer with the 2 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
b. Connect the No. 3 radiator hose to the radiator.
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 09230-01010
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 radiator with resin tank, 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.
INSTALLATION
1. INSTALL ELECTRIC COOLING FAN TO RADIATOR
Install the cooling fan with the 3 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
2. INSTALL RADIATOR ASSEMBLY
a. Install the 2 radiator support cushions and grommets to the radiator.
b. Attach the 2 grommets on the radiator to the body brackets.
c. Install the upper radiator supports with the 7 (w/o A/C) or 9 (w/ A/C) bolts.
d. Connect the upper radiator hose.
e. Connect the lower radiator hose.
f. Connect the radiator reservoir hose.
g. Connect the 2 oil cooler hoses to the oil cooler pipes.
h. Install the radiator cover with the 2 clips.
i. Connect the hone connector.
j. Connect the electric cooling fan connector.
3. INSTALL ENGINE UNDER COVERS
4. FILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR COOLANT LEAKS