Cooling System (Mechanical): Cooling: Radiator: Reassembly

INSTALL RADIATOR TANK UPPER AND LOWER
1. Check that there are no foreign objects in the lock plate groove, and install a new O-ring. Make sure the O-ring is not twisted.
  HINT:
  
  When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it.
2. Install the tank without damaging the O-ring.
  
  Fig 1: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tap the lock plate with a plastic-faced hammer so that there is no gap between the lock plate and the tank.
  
  Fig 2: Tapping Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ASSEMBLE SST
1. Install the punch assembly to part A of the overhaul handle as shown in the illustration.
  SST 09230-01010, 09231-14010
2. While gripping the handle, adjust the stopper bolt so that dimension B is as specified below.
  Dimension B:
  
  8.4 mm (0.331 in.)
  
  Fig 3: Identifying Stopper Bolt Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 bolt.
  SST 09230-01010
  
  Fig 4: Squeezing Handle Until Stopped By Stopper Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not press the protruding areas around ports A and brackets B.
    
    Fig 5: Caution For Do Not Press Protruding Areas Around Ports A And Brackets B
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Do not use SST to press the areas indicated by the circle marks in the illustration. Use pliers and be careful not to damage the core plates.
    
    Fig 6: Caution For Do Not Use SST To Press Areas Indicated By Circle Marks
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the lock plate height A after completing the caulking.
  Standard plate height A:
  
  8.8 mm (0.346 in.)
  
  If the height is not as specified, readjust the stopper bolt of the handle and caulk the lock plate again.
  
  Fig 7: Checking Lock Plate Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR DRAIN COCK PLUG
1. Install a new O-ring to the drain plug.
2. Install the drain plug.
INSPECT FOR WATER LEAKS
1. Plug the inlet and outlet pipes of the radiator with SST.
2. Using a radiator cap tester, apply pressure to the radiator.
  Standard test pressure:
  
  177 kPa (1.8 kgf/cm ² , 26 psi)
3. Submerge the radiator in water.
  
  Fig 8: Applying Pressure To Radiator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Inspect for leaks.
  HINT:
  
  On radiators with resin tanks, there is clearance between the tank and lock plate where a small amount of air will remain. This air is released when the radiator is submerged in water, giving the appearance of an air leak. Before performing the water leak test, first shake the radiator in the water until all air bubbles are released.
  
  Fig 9: Inspecting Leakage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002