Cooling System (Mechanical): Radiator: Reassembly

INSTALL OIL COOLER TO LOWER TANK
1. Install 2 new O-rings to the oil cooler.
2. Install the oil cooler to the lower tank with the 2 plate washers and nuts.
  Torque: 8.3 N.m (85 kgf.cm, 74 in.lbf)
3. Install the cooler pipe in the direction indicated in the illustration.
  Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf)
  
  Fig 1: Installing Oil Cooler To Lower Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 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.
  NOTE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.
  
  Fig 2: Inspecting Lock Plate For Damage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NEW O-RINGS AND TANKS

Fig 3: Installing New O-Rings & Tanks
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
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 4: Tap Lock Plate With Soft-Faced Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ASSEMBLE SST

Fig 5: Adjusting Stopper Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09230-01010, 09231-14010
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" is as shown in the illustration.
  Dimension: 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 plate.
  SST 09230-01010
  
  Fig 6: Caulking Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not stake the areas protruding around the pipes, brackets or tank ribs.
    
    Fig 7: Identifying Areas To Avoid Staking
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - The points shown in the illustration and oil cooler near here cannot be staked with the SST. Use pliers or similar object and be careful not to damage the core plates.
    
    Fig 8: Using Pliers To Stake Lock Plate
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the lock plate height (H) after completing the caulking.
  
  Fig 9: Checking Lock Plate Height After Completing Caulking
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Plate height: 7.40 - 7.80 mm (0.2913 - 0.3071 in.)
  
  If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
INSTALL NO.1 ECT SWITCH
1. Install a new O-ring to the No.1 ECT switch.
2. Install the No.1 ECT switch.
INSTALL DRAIN 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 pipes of the radiator with SST.
  SST 09230-01010
2. Using a radiator cap tester, apply pressure to the radiator.
  Test pressure: 177 kPa (1.8 kgf/cm ² , 26 psi)
3. Submerge the radiator in water.
  
  Fig 10: Inspecting Radiator For Water Leaks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Inspect for leaks.
  NOTE: 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. Therefore, before doing the water leak test, first swish the radiator around in the water until all air bubbles disappear.
  
  Fig 11: Identifying Air Bubbles On Radiator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002