Assembly

CAUTION: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.

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 (74 in.lb)
(e) Install the pipe (6).
Torque: 14.7 Nm (11 ft.lb)





2. Inspect the lock plate for damage.

NOTE:
- 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.

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.

CAUTION: 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) # 09230 - 01010, 09231 - 14010 or equivalent.
(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.

NOTE:





- 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 perform the caulking again.

6. Install cushion.