Removal and Installation

RADIATOR

Components:

REMOVAL
1. DRAIN ENGINE COOLANT
2. DISCONNECT RADIATOR RESERVE TANK HOSE OR PIPE
3. DISCONNECT RADIATOR HOSE INLET
4. DISCONNECT RADIATOR HOSE OUTLET
5. DISCONNECT OIL COOLER OUTLET HOSE NO.2
6. DISCONNECT OIL COOLER OUTLET HOSE NO.3

7. REMOVE AIR CLEANER INLET ASSEMBLY
a. Remove the 3 bolts and 2 air cleaner inlets.
8. REMOVE RADIATOR SUPPORT UPPER
a. Disconnect the 2 horn connectors.

b. Remove the hood lock release lever cover.

c. Remove the bolt shown in the illustration.
d. Remove the 4 bolts and radiator support.
9. REMOVE RADIATOR ASSEMBLY
a. Disconnect the fan motor connector.
b. Disconnect the ECT switch No. 1 connector.
c. Remove the radiator from the body.
10. REMOVE RADIATOR SUPPORT LOWER
11. REMOVE FAN AND MOTOR
a. Remove the 3 bolts and fan from the radiator.

DISASSEMBLY
1. REMOVE DRAIN PLUG
a. Remove the drain plug.
b. Remove the O-ring.
c. Remove the ECT switch No. 1 and gasket.

2. ASSEMBLE SST
SST 09230-01010 (09231-01010, 09231-01030)
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 bolt so that dimension B is as shown in the illustration.
Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 inch)

NOTICE: If the stopper bolt is not adjusted, the claw may be damaged.

3. REMOVE RADIATOR TANK UPPER
a. Using SST to release the caulking, grip the handle until stopped by the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01030)

4. REMOVE RADIATOR TANK LOWER
a. Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft-faced hammer and remove the tank.
b. Remove the O-ring.

5. REMOVE OIL COOLER ASSEMBLY
a. Remove the screw and pipe.
b. Remove the nut and plate washer.
c. Remove the oil cooler.
d. Remove the 2 O-rings from the oil cooler.

REASSEMBLY

1. INSTALL OIL COOLER ASSEMBLY
a. Clean the O-ring contact surface of the lower tank and oil cooler.
b. Install 2 new O-rings to the oil cooler (procedure "A").
c. Install the oil cooler to the lower tank.
d. Install the plate washer and nut (procedure "B").
Torque: 8.3 Nm (85 kgf-cm, 73 inch lbs.)
e. Install the pipe (procedure "C").
Torque: 14.7 Nm (150 kgf-cm, 11 ft. lbs.)
f. Install the screw (procedure "D").
2. INSTALL RADIATOR TANK LOWER

a. After checking that there are no foreign objects in the lock plate groove, install a 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 plate with a soft-faced hammer so that there is no gap between the lock plate and the tank.

3. ASSEMBLE SST
a. Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration.
SST 09230-01010, 09231-14010
b. While gripping the handle, adjust the stopper bolt so that dimension B shown in the illustration.
Dimension B: 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, fully caulk the lock plate by gripping the handle until stopped by the stopper plate.
SST 09230-01010

HINT:
^ Do not tap the areas protruding around the pipes, brackets or tank ribs.
^ The dotted circles shown in the illustration and parts of the oil cooler near the dotted circles (A/T) cannot be tapped with the SST Use pliers or similar objects and be careful not to damage the core plates.

b. Check the lock plate height (H) after completing the caulking.
Plate height (H): 7.40 to 7.80 mm (0.2913 to 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 gasket to the ECT switch No. 1.
b. Install the ECT switch.
Torque: 19.6 Nm (200 kgf-cm, 14 ft. lbs.)
c. Install a new O-ring to the drain plug.
d. Install the drain plug.

INSTALLATION
1. INSTALL FAN AND MOTOR
a. Install the fan to the radiator with the 3 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
2. INSTALL RADIATOR ASSEMBLY
a. Install the radiator to the body.
b. Connect the ECT switch No. 1 connector.
c. Connect the fan motor connector.
3. INSTALL RADIATOR SUPPORT UPPER
a. Install the radiator support with the 4 bolts.
Torque: 14 Nm (142 kgf-cm, 10 ft. lbs.)
b. Connect the 2 horn connectors.

4. INSTALL AIR CLEANER INLET ASSEMBLY
a. Install the 2 air cleaner inlets with the 3 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
5. ADJUST HOOD SUB-ASSEMBLY
6. ADD ENGINE COOLANT
7. CHECK FOR ENGINE COOLANT LEAKS