Cooling System (Mechanical): Radiator: Reassembly

Install Oil Cooler To Lower Tank
1. Clean the O-ring contact surface of the lower tank and oil cooler.
2. Install a new O-rings (1) to the oil cooler (2).
  
  Fig 1: Installation Sequence Of Oil Cooler To Lower Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the oil cooler with the O-rings to the lower tank (3).
4. Install the plate washers (4), and nuts (5). Torque the nuts.
  Torque: 8.3 N.m (85 kgf.cm, 74 in..lbf)
5. Install the pipe (6).
  Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf)
Inspect Lock Plate
Inspect the lock plate for damage.

Fig 2: Identifying Lock Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
NOTE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.
Install New O-Rings And Tanks
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.
  
  Fig 3: Identifying Normal O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying Correct Method Of Tapping Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Assemble SST
SST 09230-01010, 09231-14010

Fig 5: Assembling SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the punch assembly to the overhaul handle, inserting it in the hole in part "A" as shown in Fig 5.
2. While gripping the handle, adjust the stopper bolt so that dimension "B" shown in Fig 5.
  Dimension "B": 8.4 mm (0.34 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: Identifying Lock Plate Caulking Order
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  CAUTION:
  - Do not stake the areas protruding around the pipes, brackets or tank ribs.
    
    Fig 7: Identifying Bracket And Tank Rib
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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.
  Fig 8: Using Pliers To Stake Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the lock plate height (H) after completing the caulking.
  Plate height (H): 7.4 - 7.8 mm (0.2959 - 0.3119 in.)
  
  If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
Install Cushion

Fig 9: Identifying Lock Plate Height
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002