Section 460 (Engine Cooling System): Radiator: Reassembly

WARNING: This page is about a different car, the 2002 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

A/T: Install oil cooler pipes to lower tank .
1. Install 2 new O-rings to the oil cooler.
2. Install the 2 nuts.
  1. Torque: 12 N.m (120 kgf.cm, 10 ft.lbf)
3. Install the LH cooler pipe in the direction indicated in the illustration.
  1. Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf)
4. Install the RH cooler pipe.
  1. Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf)
Inspect lock plate for damage .

Fig 2: Inspecting Lock Plates For Damage
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
NOTE: 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 the new "O"-ring without twisting it.
  
  Fig 3: Installing New "O"-Rings & 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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Assemble SST .
1. SST 09230-01010,09231-14010
  
  Fig 5: Displaying SST Tool
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  1. 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 touch the stopper bolt.
  1. SST 09230-01010
  NOTE:
  - Do not stake the areas protruding around the pipes, brackets or tank ribs.
    
    Fig 7: Displaying Tank Areas
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. The points shown in Fig 7 cannot be staked with SST. Use pliers or similar object and be careful not to damage the core plates.
  
  Fig 8: Displaying Appropriate Plier Use
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the lock plate height (H) after completing the caulking.
  1. Plate height (H): 8.45 - 8.85 mm (0.3327 - 0.3484 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.
  
  Fig 9: Checking Lock Plate Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect for water leaks .
1. Tighten the drain plug.
2. Plug the inlet and outlet pipes of the radiator with SST.
  1. SST 09230-01010
    
    Fig 10: Tightening Drain Plugs Using SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a radiator cap tester, apply pressure to the radiator.
  1. Test pressure: 177 kPa (1.8 kgf/cm ² , 26 psi)
4. Submerge the radiator in water.
5. Inspect for leaks.
  
  Fig 11: Inspecting For Water Leaks
  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 bubbles disappear.