Section 272 (Engine Cooling System): Radiator: Reassembly

WARNING: This page is about a different car, the 2004 Toyota MR2, 2003 Toyota MR2, and 2002 Toyota MR2. However, it is still accessible from the selected car via links, so may be relevant.

Install New O-Rings And Tanks
1. After checking that there are no foreign objects in the lock plate groove, install the new O-ring without twisting it.
  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 1: Displaying O-Ring Proper Installment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 2: Displaying How To Tap Plate
  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.
  
  Fig 3: Displaying SST Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. While gripping the handle, adjust the stopper bolt so that dimension "B" is as shown.
  Dimension: 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 stopped plate.
  SST 09230-01010
  
  Fig 4: Caulking Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not stake the areas protruding around the pipes, brackets or tank rids.
    
    Fig 5: Displaying Areas Around The Pipes
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - The points shown cannot be staked with SST. Use wrap vinyl tape around the tip of a pair or similar object and be careful not to damage the core plates.
    
    Fig 6: Displaying Proper Staking With SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the lock plate height (H) after completing the caulking.
  1. Plate height (H): 7.4 - 7.8 mm (0.2913 - 0.3071 in.)
  If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
  
  Fig 7: Checking Lock Plate Height (H)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Drain Plug
1. Install a new O-ring to the drain plug.
2. Install the drain plug.
Inspect For Water Leaks
1. Tighten the drain plug.
2. Install the engine coolant reservoir.
3. Plug the inlet and outlet pipes of the radiator with SST. SST 09230-01010
4. Using a radiator cap tester, apply pressure to the radiator.
  1. Test pressure: 177 kPa (1.8 kgf/cm ² , 26 psi)
5. Submerge the radiator in water.
  
  Fig 8: Displaying Proper Drain Plug Tightening
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. 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 bubbles disappear.
  
  Fig 9: Inspecting For Water Leaks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002