2AZ-FE Cooling: Radiator: Reassembly

1. Check that there are no foreign objects in the core plate groove, and then install a new O-ring without twisting it.

   HINT:

   To clean the core plate groove, lightly rub it with sandpaper without scratching it.

   Fig 1: Identifying O-Ring

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2. Install the radiator tank without damaging the O-ring.
   Fig 2: Installing Radiator Tank

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3. Tap the core plate with a soft-faced hammer so that there is not gap between the core plate and radiator tank.

HINT:

Perform the same procedures as the radiator tank LH.

SST 09230-01010 (09231-01010, 09231-01020) 

1. Install the punch assembly into the overhaul handle by inserting it in the hole at 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.

   Standard dimension B: 

   8.4 mm (0.331 in.) 

   Fig 3: Identifying Stopper Bolt

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1. Lightly press SST against the core plate in the order shown in the illustration. After repeating this a few times, fully caulk the core plate by gripping the handle until stopped by the stopper bolt.

   SST 09230-01010 (09231-01010, 09231-01020) 

   Fig 4: Pressing SST Against Core Plate

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   HINT:

   • Do not tap the areas protruding around the pipes, brackets or tank ribs.
     Fig 5: Identifying Brackets Or Tank Ribs

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   • Do not tap the sections shown in the illustration or the oil cooler using SST. Use pliers or a similar tool. Be careful not to damage the core plate.
     Fig 6: Identifying Core Plate

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2. Check the core plate height (H) after completing the caulking.

   Standard plate height (H): 

   8.7 to 9.1 mm (0.343 to 0.358 in.) 

   If the height is not as specified, readjust the stopper bolt of the handle, and then caulk again.

   Fig 7: Identifying Core Plate Height

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