INSTALL UPPER RADIATOR TANK

INSTALL LOWER RADIATOR TANK

CHECK FOR WATER LEAKS

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

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 in.)

Check that there are no foreign objects in the lock plate groove, and install a new O-ring. Make sure that the O-ring is not twisted.

• HINT:

• When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it.

Tap the lock plate with a plastic hammer so that there is no gap between the lock plate and tank.

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 it is stopped by the stopper bolt.

• SST
• 09230-01010
  09231-14010

Do not tap the areas protruding around ports.

The points shown in the illustration cannot be tapped with SST. Use pliers and be careful not to damage the core plates.

Check lock plate height (H) after completing caulking.

• Plate height:
• 8.70 to 8.90 mm (0.3425 to 0.3504 mm)

If the result is not within the specified range, adjust the stopper bolt of the handle again and caulk again.

Plug the inlet and outlet pipes of the radiator with SST.

• SST
• 09230-01010

Using a radiator cap tester, apply pressure to the radiator.

• Test pressure:
• 177 kPa (1.8 kgf*cm², 26 psi)

• NOTICE:

• Do not apply more than 177 kpa (1.8 kgf*cm², 26 psi) to the radiator.

Submerge the radiator in water.

Check 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. Before doing the water leak test, first shake the radiator in the water until air bubbles disappear.