Radiator ASSY: Overhaul

1. Remove the drain plug.
2. Remove the O-ring.

SST 09230-01010

1. Install the claw 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 B: 0.2 to 0.3 mm (0.008 to 0.012 in.) 

   NOTE: If this adjustment is not performed, the claw will be damaged.
   Fig 1: Installing Claw To Overhaul Handle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST to release the caulking, grip the handle until stopped by the stopper bolt.

SST 09230-01010 (09231-01010, 09231-01030)

Fig 2: Using SST To Stopper Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a plastic hammer and remove the tank.
2. Remove the O-ring.
   Fig 3: Removing Radiator Tank Upper And Tank Lower

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 inlets.
2. Remove the 2 nuts, 2 plate washers and oil cooler.
3. Remove the 2 O-rings from the oil cooler.
   Fig 4: Removing Oil Cooler Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 2 nuts.

   Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf) 

3. Install the 2 inlets.

   Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf) 

   Fig 5: Installing Oil Cooler Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inspect the lock plate for damage.

HINT:

• If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Correct any deformations with pliers.
• Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace if necessary.
  NOTE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.
  Fig 6: Inspecting Lock Plate

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 7: 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 hammer so that there is no gap between the lock plate and the tank.
   Fig 8: Identifying Plastic Hammer

   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 B:8.4 mm (0.34 in.) 

   Fig 9: Adjusting Stopper Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 gripping the handle until stopped by the stopper plate.

   SST 09230-01010

   Fig 10: Lighting Press SST Against Lock Plate

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   • Do not tap the areas protruding around the ports (1), flange (2) and brackets (3).
     Fig 11: Identifying(1)Flange(2)And Brackets(3)

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • The points shown in the illustration cannot be tapped with SST. Use pliers and be careful not to damage the core plates.
     Fig 12: Using Pliers And Be Careful

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the lock plate height (H) after completing the caulking

   Plate height (H): 8.8 mm (0.346 in.) 

   If not within the specified height, adjust the stopper bolt of the handle again and caulk the lock plate again.

   Fig 13: Identifying Measuring Plate Height

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new O-ring to the drain plug.
2. Install the drain plug.

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 14: Using A Radiator Cap Tester

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Inspect for leaks.

   HINT:

   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. Before doing the water leak test, first shake the radiator in the water until all air bubbles disappear.