INSTALL OIL COOLER (for Automatic Transmission)
INSPECT LOCK PLATE FOR DAMAGE
INSTALL UPPER RADIATOR TANK AND LOWER RADIATOR TANK
ASSEMBLE SST
CAULK LOCK PLATE
INSTALL RADIATOR DRAIN COCK PLUG
INSPECT FOR WATER LEAKS
INSTALL RADIATOR BRACKET SUB-ASSEMBLY
| 1. INSTALL OIL COOLER (for Automatic Transmission) |
Install 2 new O-rings to the oil cooler.
Install the oil cooler and 2 plate washers to the lower tank with the 2 nuts.
- Torque:
- 8.3 N*m{85 kgf*cm, 74 in.*lbf}
Install the 2 cooler pipes.
- Torque:
- 15 N*m{150 kgf*cm, 11 ft.*lbf}
- HINT:
- Set the cooler pipe labeled A to the location and angle shown in the illustration.
| 2. INSPECT LOCK PLATE FOR DAMAGE |
Inspect the lock plate for damage.
Text in Illustration*1
| Lock Plate
|
*2
| Core
|
If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Correct any deformations with pliers.
Water will leak if the bottom of the lock plate groove is damaged or dented. Repair or replace it if necessary.
- NOTICE:
- The radiator can only be recaulked twice. After the second time, the radiator core must be replaced.
| 3. INSTALL UPPER RADIATOR TANK AND LOWER RADIATOR TANK |
Check that there are no foreign objects in the lock plate groove, and then install a new O-ring. Make sure the O-ring is not twisted.
Text in Illustration*1
| O-Ring
|
*a
| CORRECT
|
*b
| INCORRECT
|
*c
| Normal
|
*d
| Twisted
|
- HINT:
- When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it.
Install the tank without damaging the O-ring.
Tap the lock plate with a plastic-faced hammer so that there is no gap between the lock plate and tank.
Text in Illustration*1
| Tank
|
*2
| Lock Plate
|
*a
| CORRECT
|
*b
| INCORRECT
|
Install the punch assembly to part A of the overhaul handle as shown in the illustration.
- SST
- 09230-01010(09231-01010,09231-01020)
09231-14010
Text in Illustration*1
| Dimension B
|
*2
| Part A
|
*3
| Stopper Bolt
|
While gripping the handle, adjust the stopper bolt so that dimension B is as specified below.
- Dimension B:
- 8.4 mm (0.331 in.)
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 stopper bolt.
- SST
- 09230-01010(09231-01010,09231-01020)
09231-14010
Text in Illustration*1
| Stopper Bolt
|
*2
| Tank
|
*3
| Lock Plate
|
- NOTICE:
- Do not press the protruding areas around the ports (1) and bracket (2).
- Do not use SST to press the areas indicated by the circle marks in the illustration. Use pliers and be careful not to damage the core plates.
Check the lock plate height H after completing the caulking.
- Standard plate height H:
- 8.8 mm (0.346 in.)
If the height is not as specified, readjust the stopper bolt of the handle and caulk the lock plate again.
| 6. INSTALL RADIATOR DRAIN COCK PLUG |
Install a new O-ring to the drain plug.
Install the drain plug.
| 7. INSPECT FOR WATER LEAKS |
Plug the inlet and outlet pipes of the radiator with SST.
- SST
- 09230-01010(09231-00030,09231-00060)
Using a radiator cap tester, apply pressure to the radiator.
- Standard test pressure:
- 177 kPa (1.8 kgf/cm2, 26 psi)
Submerge the radiator in water.
Inspect for leaks.
Text in Illustration*1
| Tank
|
*2
| Lock Plate
|
*3
| O-Ring
|
- HINT:
- On radiators with resin tanks, there is clearance between the tank and lock plate where a small amount of air will remain. This air is released when the radiator is submerged in water, giving the appearance of an air leak. Before performing the water leak test, first shake the radiator in the water until all air bubbles are released.
| 8. INSTALL RADIATOR BRACKET SUB-ASSEMBLY |
Install the 2 brackets with the 4 bolts.
- Torque:
- 13 N*m{130 kgf*cm, 9 ft.*lbf}
