Engine Cooling System: Radiator: Reassembly

A/T (DENSO Made): Install oil cooler to lower tank.
1. Install 2 new O-rings to the oil cooler.
  
  Fig 1: Installing New O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the oil cooler to the lower tank.
3. Install the 2 plate washers and 2 nuts.
  1. Torque: 8.34 N.m (85 kgf.cm, 74 in..lbf)
DENSO Made: 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.
  
  Fig 2: Confirming That O-Ring Is Not Twisted
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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 3: Tapping Lock Plate With Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DENSO Made: Assemble SST.
1. 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 Fig 4.
  
  Fig 4: Assembling SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. While gripping the handle, adjust the stopper bolt so that dimension "B" is as shown in Fig 4.
  1. Dimension: 8.4 mm (0.331 in.)
DENSO Made: Caulk lock plate.
1. Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, stopped by the stopped plate.
  1. SST 09230-01010
  NOTE:
  - Do not stake the areas protruding around the pipes, brackets or tank rids.
    
    Fig 6: Identifying Areas Not To Stake
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - The points shown in Fig 7 cannot be staked with SST. Wrap vinyl tape around the tip of a pair pliers or similar object and be careful not to damage the core plates.
    
    Fig 7: Using Pliers To Stake Ends
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the lock plate height (H) after completing the caulking.
  
  Fig 8: Checking Plate Height After Caulking
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Plate height (H): 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 drain plug.
1. Install a new O-ring to the drain plug.
2. Install the drain plug.
Inspect for water leaks.
1. Tighten the drain plug.
2. Plug the inlet and outlet pipes of the radiator with SST.
  1. SST 09230-01010
3. Using a radiator cap tester, apply pressure to the radiator.
  1. Test pressure: 177 kPa (1.8 kgf/cm² , 26 psi)
4. Submerge the radiator in water.
5. Inspect for leaks.
  
  Fig 10: Inspecting For Leaks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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 bubbles disappear.