Section 8 (Radiator): Reassembly

WARNING: This page is about a different car, the 2001 Lexus GS 300. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL OIL COOLER TO LOWER TANK.
1. Install 2 new O-rings to the oil cooler.
2. Install the oil cooler to the lower tank with the 2 plate washers and 2 nuts.
  1. Torque: 8.3 N.m (85 kgf.cm, 74 in. lbf)
3. Install the cooler pipes in the direction indicated. See Fig 1.
  1. Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf)
INSPECT 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.
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 a new O-ring without twisting it.
  NOTE: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.
  
  Fig 2: Identifying Proper Installation Of New Lock Plate 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 3: Installing Lock Plate To Radiator Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 4.
2. While gripping the handle, adjust the stopper bolt to dimension B. See Fig 4.
  1. Dimension B: 8.4 mm (0.331 in.)
CAULK LOCK PLATE.
1. Lightly press SST (SST 09230-01010) against the lock plate in the order shown. See Fig 5 After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper plate.
  
  Fig 5: Caulking Lock Plate To Radiator Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not stake the areas protruding around the ports (1), flange (2) and bracket (3). See Fig 6.
  - The points shown cannot be staked with the SST. See Fig 7. Use pliers or similar object and be careful not to damage the core plates.
  Fig 6: Identifying Areas Not To Be Staked
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 7: Identifying Points To Be Staked With Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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): 7.40-7.80 mm (0.2913-0.3071 in.)
  Fig 8: Checking Lock Plate Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ECT SWITCH.
1. Install a new O-ring to the ECT switch.
2. Install the ECT switch.
INSTALL DRAIN PLUG.
1. Install a new O-ring to the drain plug.
2. Install the drain plug.
INSTALL RADIATOR CAP.
INSPECT FOR WATER LEAKS.
1. Tighten the drain plug.
2. Plug the inlet pipes of the radiator with SST (SST 09230-01010).
  
  Fig 9: Plugging Radiator Inlet Pipes With SST 09230-01010
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  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 air bubbles disappear.
INSTALL NEW PACKINGS.