Radiator ASSY: Overhaul

1. Remove the drain cock plug.
2. Remove the O-ring from the drain cock plug.

SST 09230-01010 (09231-01010, 09231-01030)

1. Install the claw to the overhaul handle by inserting it in the hole in part "A" as shown in Fig 1 .
2. While gripping the handle, adjust the stopper bolt so that dimension "B" is as shown in Fig 1 .

   Dimension "B" 0.2 to 0.3 mm (0.008 to 0.012 in) 

   NOTE: If the stopper bolt is not adjusted, the claw may be damaged.

Fig 1: Installing Claw To Overhaul Handle Inserting Hole In Part "A"

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST to release the core plate, grip the handle until stopped by the stopper bolt.

   SST 0923-01010 (09231-01010, 09231-01030)

   Fig 2: Releasing Core Plate Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Lightly tap the bracket of the radiator tank (or radiator tank pipe) with a soft-faced hammer, then remove the radiator tank.
   Fig 3: Lightly Tapping Bracket Of Radiator Tank

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the O-ring.

HINT:

Perform the same procedures as the radiator tank upper.

1. Remove the bolt.
2. Remove the nut and inlet No.1.
   Fig 4: Removing Inlet No. 1

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the nut and inlet No.2.
   Fig 5: Identifying Inlet No. 2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 nuts and 2 washers, then remove the oil cooler from the radiator tank.
   Fig 6: Removing ATM Oil Cooler

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 O-rings from the oil cooler.

Check the core plate for damage.

HINT:

• If the sides of the core plate groove are deformed, it will be impossible to reassemble the radiator tank. Therefore, first correct any deformation with pliers or a similar tool.
• Water leakage will result if the bottom of the core plate groove is damaged or dented. Repair or replace if necessary.
  NOTE: The radiator can only be recaulked 2 times. After being recaulked 2 times, the radiator core must be replaced.
  Fig 7: Inspecting Radiator Core

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 2 new O-rings to the oil cooler.
2. Install the oil cooler to the radiator tank.
3. Install the 2 nuts and 2 washers.

   Torque: 8.3 N.m (85 kgf.cm, 74 in.lbf) 

   Fig 8: Installing ATM Oil Cooler

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 15 N.m (150 kgf.cm, 11 ft.lbf) 

Torque: 15 N.m (150 kgf.cm, 11 ft.lbf) 

1. After checking that there are no foreign objects in the core plate groove, install a new O-ring without twisting it.

   HINT:

   When cleaning the core plate groove, lightly rub it with sandpaper without scratching it.

   Fig 9: Installing O-Ring Without Twisting

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the radiator tank without damaging the O-ring.
   Fig 10: Installing Radiator Tank

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tap the core plate with a soft-faced hammer so that there is no gap between the core plate and radiator tank.

HINT:

Perform the same procedures as the radiator tank upper.

SST 09230-01010 (09231-01010, 09231-01020)

1. Install the punch assembly to the overhaul handle by inserting it in the hole in part "A" as shown in Fig 11 .
   Fig 11: Installing Punch Assemby To Overhaul Handle Inserting In Part "A"

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. While gripping the handle, adjust the stopper bolt so that dimension "B" is as shown in Fig 11 .

   Dimension "B": 8.4 mm (0.341 in.) 

1. Lightly press SST against the core plate in the order shown in Fig 14 . After repeating this a few times, fully caulk the core plate by gripping the handle until stopped by the stopper bolt.

   SST 09230-01010 (09231-01010, 09231-01020)

   Fig 12: Pressing SST Against Core Plate By Stopper Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   • Do not tap the areas protruding around the pipes, brackets or tank ribs.
     Fig 13: Identifying Rib & Bracket

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • The points shown in Fig 14 and oil cooler near here cannot be tapped with the SST. Use pliers or a similar tool and be careful not to damage the core plate.
     Fig 14: Lightly Pressing SST Against Core Plate

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the core plate height (H) after completing the caulking.

   Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.) 

   If the height is not as specified, adjust the stopper bolt of the handle again, then caulk again.

   Fig 15: Identifying Core Plate Height

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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