Cooling System (Mechanical): Cooling: Radiator: Reassembly

1. INSTALL OIL COOLER TO LOWER TANK 

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 2 nuts.
   1. Torque: 8.3 N.m (85 kgf.cm, 74 in.lbf) 
3. Install the cooler pipes in the direction indicated in the illustration.
   1. Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf) 
   Fig 1: Installing Oil Cooler To Lower Tank

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

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

   HINT:

   When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.

   Fig 2: Installing New O-Ring Without Twisting

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 3: Tapping Lock Plate With Soft-Faced Hammer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 4 .
2. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in Fig 4 .
   1. Dimension B: 8.4 mm (0.331 in.) 
Fig 4: Assembling SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Lightly press SST against the lock plate in the order shown in Fig 5 . After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper plate.

   SST 09230-01010

   Fig 5: Lightly Pressing SST Against Lock Plate

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   • Do not stake the areas protruding around the ports (1), flange (2) and bracket (3).
     Fig 6: Do Not Stake Areas Around Ports, Flange And Bracket

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • The points shown in Fig 7 cannot be staked with the SST. Use pliers or similar object and be careful not to damage the core plates.
     Fig 7: Points Shown Cannot Be Staked

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

   Fig 8: Checking Lock Plate Height (H) After Completing Caulking

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new O-ring to the ECT switch.
2. Install the ECT switch.

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

1. Tighten the drain plug.
2. Plug the inlet pipes of the radiator with SST.

   SST 09230-01010

   Fig 9: Plugging Inlet Pipes Of Radiator With 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.

   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.

   Fig 10: Inspecting For Leaks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002