Section 372 (Radiator): Reassembly

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

A/T (DENSO Made):
1. INSTALL OIL COOLER TO LOWER TANK
1. Clean the O-ring contact surface of the lower tank and oil cooler.
2. Install 2 new O-rings to the oil cooler.
3. Install the oil cooler to the lower tank.
4. Install the 2 plate washers and 2 nuts.
  Torque: 8.34 N.m (85 kgf.cm, 74 in..lbf)
  
  Fig 1: Installing New O-Rings To Oil Cooler
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the cooler pipe in the direction indicated as shown in the illustration.
  1. Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf)
    
    Fig 2: Installing Cooler Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DENSO Made:
1. 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.
  HINT:
  
  When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.
2. Install the tank without damaging the O-ring.
  
  Fig 3: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tap the lock prate 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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DENSO Made:
1. ASSEMBLE SST
2. 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.
2. While gripping the handle, adjust the stopper bolt so that dimension "B" is as shown in the illustration.
  1. Dimension: 8.4 mm (0.331 in.)
    
    Fig 5: Installing Punch Assembly To Overhaul Handle
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DENSO Made:
1. 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.
  1. SST 09230-01010
    
    Fig 6: Caulking Lock Plate
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  HINT:
  - Do not stake the areas protruding around the pipes, brackets or tank rids.
    
    Fig 7: Identifying Non-Staking Area Around Cooler Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - The points shown in the illustration and oil cooler near here (A/T) 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 8: Caulking Lock Plate
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the lock plate height (H) after completing the caulking.
  1. Plate height: 7.40 - 7.80 mm (0.2913 - 0.3071 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: Identifying Lock Plate Height After Completing Caulking
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  1. 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 10: Tightening Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Inspect for leaks.
  HINT:
  
  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 11: Identifying Clearance Between Tank And Lock Plate Where Minute Amount Of Air Remain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002