Engine Cooling System: Radiator: Reassembly

Inspect the lock plate for damage.

Fig 1: Inspecting Lock Plate

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1. After checking that there are no foreign objects in the lock plate groove, install the new O-ring without twisting it.
   NOTE:

   When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.

   Fig 2: Displaying Proper O-Ring Installation

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2. Install the tank without damaging the O-ring.
3. Tap the lock plate with a soft-faced hammer so that there is no gap between it and the tank.
   Fig 3: Installing Tank Without Damaging O-Ring

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1. SST 09230-01010

1. Install the punch assembly to the overhaul handle, inserting it in the hole in part "A" as shown in the illustration.
2. While gripping the handle, adjust the stopper bolt so that dimension "B" shown in the diagram.
   1. Dimension "B": 8.4 mm (0.34 in.) 
   Fig 4: Displaying SST Assembly

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1. 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.
   1. SST 09230-01010
   Fig 5: Caulking Lock Plate

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   NOTE:

   • Do not stake the areas protruding around the ports.
     Fig 6: Locating Port In Radiator

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   • The points shown in the rib sides near here cannot be staked with SST. Use pliers or similar object and be careful not to damage the core plates.
2. Check the lock plate height (H) after completing the caulking.
   1. Plate height (H): 7.4 - 7.8 mm (0.2959-0.3119 in.) 
   Fig 7: Using Pliers To Install Lock Plate
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If not within the specified height, adjust the stopper bolt of the handle again and caulk again.

1. Install a new O-ring to the drain plug.
2. Apply soapy water to the O-ring
3. Install the drain plug.
   Fig 8: Checking Lock Plate Height

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1. Using SST, plug the inlet and outlet pipes of the radiator.
   1. SST 09230-01010
2. Using a radiator cap tester, apply pressure to the radiator.
   1. Test pressure: 177 kPa (1.8 kgf/cm ²  , 26 psi) 
   Fig 9: Plugging Inlet & Outlet Pipes

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3. Check for water leaks.
   NOTE:

   On radiators with resin tanks, there is a clearance between the core plate and tank where a minute amount of air will remain, giving the appearance of an air leak when the radiator is sub merged in water. Therefore, before performing the water leak test, first swirl the radiator around in the water until all air bubbles disappear.

1. Torque: 12.7 N.m (130 kgf.cm, 9 ft.lbf)