Section 8 (Engine Cooling System (1GR-FE)): Radiator: Reassembly

WARNING: This page is about a different car, the 2008 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL RADIATOR TANK
1. Check that there are no foreign objects in the lock plate groove, and install a new O-ring. Make sure the O-ring is not twisted.
  HINT:
  
  When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it.
  
  Fig 1: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the tank without damaging the O-ring.
3. Tap the lock plate with a plastic-faced hammer so that there is no gap between the lock plate and the tank.
  
  Fig 2: Tapping Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ASSEMBLE SST
1. Install the punch assembly to part A of the overhaul handle as shown in the illustration.
  SST 09230-01010, 09231 -14010
  
  Fig 3: Installing Punch Assembly To Part A Of Overhaul Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. While gripping the handle, adjust the stopper bolt so that dimension B is as specified below.
  Dimension B: 8.4 mm (0.331 in.)
CAULK LOCK PLATE
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.
  SST 09230-01010
  
  Fig 4: Pressing SST Against Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not press the protruding areas around the ports (1) and brackets (2).
    
    Fig 5: Identifying Protruding Areas Around Ports (1) And Brackets (2)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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.
    
    Fig 6: Precaution For Press Core Plates Areas
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 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.
INSTALL RADIATOR DRAIN COCK PLUG
1. Install a new O-ring to the drain plug.
2. Install the drain plug.
INSPECT FOR WATER LEAKS
1. Plug the inlet and outlet ports of the radiator with SST
  SST 09230-01010
  
  Fig 8: Plugging Inlet And Outlet Ports Of Radiator With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a radiator cap tester, apply pressure to the radiator.
  Standard test pressure: 177 kPa (1.8 kgf/cm ² , 26 psi)
3. Submerge the radiator in water.
4. Inspect for leaks.
  HINT:
  
  For 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 water until all air bubbles are released.
  
  Fig 9: Inspecting For Leaks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR BRACKET SUB-ASSEMBLY
1. Install the 2 brackets with the 4 bolts.
  Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
  
  Fig 10: Identifying Brackets Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002