Cooling System (Mechanical): Radiator: Reassembly

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.
3. Install the 2 inlet sub-assembly.
  
  Fig 1: Installing 2 New O Rings To Oil Cooler
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 11.8 N.m (120 kgf.cm, 9 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.
  CAUTION: 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.
  
  Fig 3: Installing New O-Rings And Tanks
  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 4: Tapping Lock Plate With Soft-Faced Hammer
  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 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.)
CAULK LOCK PLATE
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.
  
  Fig 6: Caulking Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09230-01010
  NOTE:
  - Do not stake the areas protruding around the ports (1), flange (2) and bracket (3).
    
    Fig 7: Identifying Areas Protruding Around Ports Flange And Bracket
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - The points shown in Fig 7 cannot be staked with the SST. Use pliers or similar object and be careful not to damage the core plates.
    
    Fig 8: Using Pliers To Staked Points
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the lock plate height (H) after completing the caulking.
  
  Fig 9: Checking Lock Plate Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Plate height (H): 8.8 mm (0.346 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.
INSTALL RADIATOR CAP
INSPECT FOR WATER LEAKS
1. Tighten the drain plug.
2. Plug the inlet pipes of the radiator with SST.
  
  Fig 10: Plugging Inlet Pipes Of Radiator With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09230-01010
3. Using a radiator cap tester, apply pressure to the radiator.
  Test pressure: 177 kPa (1.8 kgf/cm ² , 26 psi)
4. Submerge the radiator in water.
5. Inspect for leaks.
  
  Fig 11: Identifying Lock Plate, Tank And O-Ring
  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 air bubbles disappear.
INSTALL NEW PACKINGS