Radiator: Service and Repair
REMOVAL
HINT:
At the time of installation, please refer to the following items.
^ Start the engine, and check for coolant and A/T fluid leaks.
^ Check the A/T fluid level.
1. REMOVE BATTERY AND BATTERY TRAY
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT
4. DISCONNECT NO.3 ENGINE ROOM RELAY BLOCK FROM RADIATOR
5. DISCONNECT NO.1 COOLING FAN CONNECTOR
6. DISCONNECT WIRE CLAMPS FROM NO.1 FAN SHROUD
7. DISCONNECT NO.2 COOLING FAN CONNECTOR
8. DISCONNECT NO.1 ECT SWITCH WIRE CONNECTOR
9. DISCONNECT WIRE CLAMPS FROM NO.2 FAN SHROUD
10. DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR
11. DISCONNECT LOWER RADIATOR HOSE FROM RADIATOR
12. DISCONNECT A/T OIL COOLER HOSES FROM RADIATOR
13. REMOVE RADIATOR AND COOLING FANS ASSEMBLY
a. Remove the 2 bolts and 2 upper supports.
Torque: 12.8 Nm (130 kgf.cm, 9 ft. lbs.)
b. Lift out the radiator, and remove the radiator and cooling fans assembly.
c. Remove the 2 lower supports.
14. REMOVE NO.1 ECT SWITCH
15. REMOVE NO.1 COOLING FAN FROM RADIATOR
Remove the 2 bolts and cooling fan.
Torque: 5.0 Nm (50 kgf.cm, 44 inch lbs.)
16. REMOVE NO.2 COOLING FAN FROM RADIATOR
Remove the 2 bolts and cooling fan.
Torque: 5.0 Nm (50 kgf.cm, 44 inch lbs.)
DISASSEMBLY
1. REMOVE CUSHION FROM RADIATOR
2. 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 diagram.
b. While gripping the handle, adjust the stopper bolt so that dimension "B" shown in the diagram is 0.2 - 0.5 mm (0.008 - 0.020 inch).
NOTICE: If this adjustment is not done, the claw may be damaged.
3. UNCAULK LOCK PLATES
Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt.
SST 09230-01010
4. REMOVE TANKS AND O-RINGS
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 FROM LOWER TANK
a. Remove the pipe.
b. Remove the nuts and plate washers.
c. Remove the oil cooler and O-rings.
REASSEMBLY
1. INSTALL OIL COOLER TO LOWER TANK
a. Clean the O-ring contact surface of the lower tank and oil cooler.
b. Install a new O-rings (1) to the oil cooler (2).
c. Install the oil cooler with the O-rings to the lower tank (3).
d. Install the plate washers (4), and nuts (5). Torque the nuts.
Torque: 8.3 Nm (85 kgf.cm, 74 inch lbs.)
e. Install the pipe (6).
Torque: 14.7 Nm (150 kgf.cm, 11 ft. lbs.)
2. INSPECT LOCK PLATE
Inspect the 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 or dented, Therefore, repair or replace if necessary.
NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.
3. 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 plate with a soft-faced hammer so that there is no gap between it and the tank.
4. 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" shown in the diagram.
Dimension "B": 8.4 mm (0.34 inch)
5. 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 squeezing the handle until stopped by the stopper plate.
SST 09230-01010
HINT:
^ Do not stake the areas protruding around the pipes, brackets or tank ribs.
^ The points shown in the rib sides and oil cooler near here cannot be staked with SST. Use pliers 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 (H): 7.4 - 7.8 mm (0.2959 - 0.3119 inch)
If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
6. INSTALL CUSHION
INSTALLATION
Installation is in the reverse order of removal.