Cooling System (Mechanical): Radiator: Reassembly

1. Install 2 new O rings to the oil cooler.
Fig 1: Installing 2 New O Rings To Oil Cooler
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2. Install the oil cooler to the lower tank.
3. Install the 2 inlet sub-assembly.

   Torque: 11.8 N.m (120 kgf.cm, 9 ft.lbf) 

HINT:

• If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible.
Fig 2: Inspecting Lock Plate For Damage
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• 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.

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 3: Installing New O-Rings
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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
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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.
Fig 5: Adjusting Stopper Bolt
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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.) 

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 6: Caulking Lock Plate

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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
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   • The points shown in the illustration cannot be staked with the SST. Use pliers or similar object and be careful not to damage the core plates.
   Fig 8: Using Plier To Staked Points
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2. Check the lock plate height (H) after completing the caulking.

   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.

Fig 9: Checking Lock Plate Height
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1. Install a new O-ring to the drain plug.
2. Install the drain plug.

1. Tighten the drain plug.
2. Plug the inlet pipes of the radiator with SST.

   SST 09230-01010

Fig 10: Plugging Inlet Pipes Of Radiator With SST
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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.
   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.
   Fig 11: Radiator With Resin Tank Releasing Bubbles

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002