Engine Cooling System: Radiator: Reassembly

1. After checking that there are no foreign objects in the lock plate groove, install the new O-ring without twisting it.

   HINT:

   When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.

2. Install the tank without damaging the O-ring.
   Fig 1: Installing O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tap the lock plate with a soft-faced hammer so that there is no gap between it and the tank.
   Fig 2: Taping Lock Plate With A Soft-Faced Hammer

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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.) 

Fig 3: Assembling SST

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 squeezing the handle until stopped by the stopper plate.

   SST 09230-01010

   Fig 4: Pressing SST Against Lock Plate

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   • Do not stake the areas protruding around the pipes, brackets or tank rids.
     Fig 5: Identifying Protruding Areas Around Pipes, Brackets And Tank Rids

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • The points shown in the illustration cannot be staked with SST. Wrap vinyl tape around the tip of a pair or similar object and be careful not to damage the core plates.
     Fig 6: Identifying Areas Unable To Be Staked With SST

     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 (0.2913 - 0.3071 in.) 

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

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

Fig 7: Checking Lock Plate Height

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1. Tighten the drain plug.
2. Install the engine coolant reservoir.
3. Plug the inlet and outlet pipes of the radiator with SST.

   SST 09230-01010

4. Using a radiator cap tester, apply pressure to the radiator.

   Test pressure: 177 kPa (1.8 kgf/cm ²  , 26 psi) 

5. Submerge the radiator in water.
   Fig 8: Plugging Inlet And Outlet Pipes Of Radiator With SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. 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. Therefore, before doing the water leak test, first swish the radiator around in the water until all bubbles disappear.

   Fig 9: Inspecting Radiator Tank For Leaks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002