Section 71 (Engine Cooling System): Radiator: Reassembly

WARNING: This page is about a different car, the 2007 Lexus ES 350. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL RADIATOR TANK UPPER
1. Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration.
  SST 09230-01010, 09231-14010
  
  Fig 1: Adjusting Stopper Bolt - Dimension B
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. After checking that there are no foreign objects in the lock plate groove, install a new O-ring without twisting it.
  HINT:
  
  When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.
  
  Fig 2: Identifying O-Ring Without Twisting
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the tank without damaging the O-ring.
  
  Fig 3: Tapping Lock Plate With Soft-Faced Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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 gripping the handle until stopped by the stopper plate.
  HINT:
  - Do not tap the areas protruding around the pipes, brackets or tank ribs.
  - The dotted circles shown in the illustration and parts of the oil cooler near the dotted circles cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates.
    
    Fig 4: Pressing SST Against Lock Plate
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check the lock plate height (H) after completing caulking.
  Plate height (H):
  
  7.40 to 7.80 mm (0.2913 to 0.3071 in.)
  
  If not within the specified height range, adjust the stopper bolt of the handle and caulk again.
6. Tap the lock plate with a soft-faced hammer so that there is no gap between the lock plate and the tank.
  
  Fig 5: Measuring Plate Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR TANK LOWER
1. Without hose:
  1. Clean the O-ring contact surfaces of the lower tank and oil cooler.
  2. Install 2 new O-rings to the oil cooler (D).
  3. Install the oil cooler to the lower tank (C).
  4. Install the plate washer and nut (B).
    Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf)
  5. Install the cooler pipe with the bolt (A).
    Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf)
    
    Fig 6: Identifying Cooler Pipe With Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Installation procedure of the radiator tank lower is the same as that of the radiator tank upper.
3. With hose:
  1. Install the hose with the bolt and 2 clips.
    Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf)
INSTALL DRAIN PLUG
1. Install a new O-ring to the drain plug.
2. Install the drain plug.
  
  Fig 7: Locating O-Ring To Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FOR WATER LEAKS
1. Plug the inlet and outlet pipes of the radiator with SST.
  SST 09230-01010
2. Using the radiator cap tester, apply pressure to the radiator.
  Test pressure:
  
  177 kPa (1.8 kgf/cm ² , 26 psi)
3. Submerge the radiator in water.
  
  Fig 8: Identifying Inlet And Outlet Pipes Of Radiator With SST
  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 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 9: Identifying Clearance Between Tank And Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002