Engine Cooling System: Radiator: Reassembly

1. Clean the O-rings contact surface of the lower tank and oil cooler.
2. Install 2 new O-rings to the oil cooler.
3. Install the oil cooler to the lower tank.
4. Install the plate washer and nut.

   Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 

5. Install the cooler pipe.

   Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf) 

6. Install the screw.
   Fig 1: Installing Oil Cooler To Lower Tank

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. After checking that there are no foreign objects in the lock plate groove, install a 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 2: Identifying 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 the lock plate and the tank.

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 (0.331 in.) 

Fig 4: Installing Punch Assembly To Overhaul Handle

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 

   HINT:

   • Do not tap the areas protruding around the pipes, brackets or tank ribs.
   • The dotted circles shown in the illustration and parts of the oil cooler near the dotted circles cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates.
   Fig 5: Caulking Lock Plate

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

   Plate height (H): 

   7.40 to 7.80 mm (0.2913 to 0.3071 in.) 

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

Fig 6: Measuring Plate Height

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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 

Fig 7: Plugging Inlet And Outlet Pipes Of Radiator With SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
4. Inspect for leaks.

   HINT:

   On radiators with resin tanks, there is 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 air bubbles disappear.

Fig 8: Inspecting For Water Leaks

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002