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).
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.
  1. Torque: 8.3 N.m (85 kgf.cm, 74 in. lbf)
5. Install the pipe (6).
  1. Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf)
Fig 1: Installing Oil Cooler To Lower Tank
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect lock plate. Inspect the lock plate for damage.
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.

Fig 2: Inspecting Radiator Lock Plate
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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.
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: Identifying Proper Installation Of New Lock Plate O-Ring
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Fig 4: Installing Lock Plate To Radiator Tank
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Assemble SST. (SST 09230-01010, 09231-14010).
1. Install the punch assembly to the overhaul handle, inserting it in the hole in part "A". See Fig 5.
2. While gripping the handle, adjust the stopper bolt so that dimension "B". See Fig 5.
  1. Dimension "B": 8.4 mm (0.34 in.)
Fig 5: Assembling Special Service Tool 09230-01010
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Caulk lock plate.
1. Lightly press SST against the lock plate in the order shown. See Fig 6. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper plate of SST 09230-01010.
  NOTE:
  - Do not stake the areas protruding around the pipes, brackets or tank ribs.
  - 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.
2. Check the lock plate height (H) after completing the caulking. If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
  1. Plate height (H): 7.4-7.8 mm (0.2959-0.3119 in.)
Fig 6: Caulking Lock Plate To Radiator Tank
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 7: Identifying Areas On Tank That Cannot Be Staked With SST
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Fig 8: Staking Rib Sides & Oil Cooler With Pliers
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Fig 9: Checking Lock Plate Height
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Install cushion.