Section 121 (Radiator): Radiator: Reassembly

1. Install 2 new O-rings to the oil cooler.
2. Install the oil cooler to the lower tank with the 2 plate washers and nuts.
   1. Torque: 8.3 N.m (85 kgfcm, 74 in.lbf) 
3. Install the cooler pipe in the direction indicated in Fig 1.
   1. Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf) 
   Fig 1: Installing Oil Cooler To Lower Tank

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HINT:

• 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 or dented.

Fig 2: Inspecting Lock Plate For Damage

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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.

   Fig 3: Installing New O-Ring Without Twisting It

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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: Taping Lock Plate With Soft-Faced Hammer

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1. 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 Fig 5.
2. While gripping the handle, adjust the stopper bolt so that dimension "B" is as shown in Fig 5.
   1. Dimension: 8.4 mm (0.331 in) 
   Fig 5: Assembling SST

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1. Lightly press SST against the lock plate in the order shown in Fig 6. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper 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 ribs.
     Fig 7: Identifying Areas Protruding Around Pipes, Brackets Or Tank Ribs

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   • The points shown in Fig 8 and oil cooler near here cannot be staked with the SST. Use pliers or similar object and be careful not to damage the core plates.
   Fig 8: Using Pliers To Stake Parts

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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.

1. Install a new O-ring to the No.1 ECT switch.
   Fig 9: Checking Lock Plate Height After Completing Caulking

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2. Install the No.1 ECT switch.

1. Install a new O-ring to the drain plug.
2. Install the drain plug.

1. Plug the inlet and outlet pipes of the radiator with SST.
   Fig 10: Plugging Inlet And Outlet Pipes Of Radiator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. SST 09230-01010
2. Using a radiator cap tester, apply pressure to the radiator.
   1. Test pressure: 177 kPa (1.8 kgf/cm ²  , 26 psi) 
3. Submerge the radiator in water.
   Fig 11: Inspecting radiator For Leaks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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 air bubbles disappear.