Section 11 (Cooling): Radiator: Reassembly

WARNING: This page is about a different car, the 2007 Lexus SC 430. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL OIL COOLER
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.
  Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
3. Install the 2 inlets.
  Torque: 14.7 N*m (150 kgf*cm, 11 ft.*lbf)
  
  Fig 1: Identifying Oil Cooler Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR TANK
1. Check that the lock plate groove is free from foreign objects.
  If necessary, clean the lock plate groove by lightly rubbing it with sandpaper.
  
  NOTE: Do not scratch the lock plate groove.
2. Install a new O-ring.
3. Check that the O-ring is not twisted.
4. Install the tank without damaging the O-ring.
  
  Fig 2: Checking Lock Plate Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Tap the lock plate with a plastic-faced hammer so that there is no gap between the lock plate and the tank.
  
  Fig 3: Tapping Lock Plate With Plastic-Faced Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CAULK LOCK PLATE
1. Install the punch assembly to part A of the overhaul handle as shown in the illustration.
  SST 09230-01010, 09231-14010
2. While gripping the handle, adjust the stopper bolt so that dimension B is as specified below.
  Dimension B:
  
  8.4 mm (0.33 in.)
  
  Fig 4: Identifying Punch Assembly To Part A Of Overhaul Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. 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 stopper bolt.
  SST 09230-01010, 09231-14010
  
  Fig 5: Pressing SST Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not press the protruding areas around the ports A, flange B and bracket C.
    
    Fig 6: Identifying Ports, Flange And Bracket
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Do not press the circled areas in the illustration. Use pliers and be careful not to damage the core plates.
  Fig 7: Pressing Core Plates
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check the lock plate height H after completing the caulking.
  Plate height H:
  
  8.8 mm (0.346 in.)
  
  If the height is not within the specified height, readjust the stopper bolt of the handle and caulk the lock plate again.
  
  Fig 8: Checking Lock Plate Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR DRAIN COCK PLUG
1. Install a new O-ring to the drain plug.
2. Install the drain plug.
INSPECT WATER LEAK
1. Plug the inlet and out let pipes of the radiator with SST.
  SST 09230-01010
2. Using a radiator cap tester, apply pressure to the radiator.
  Test pressure:
  
  177 kPa (1.8 kgf/cm ² , 26 psi)
3. Submerge the radiator in water.
  
  Fig 9: Inspecting Water Leak
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Inspect for leaks.
  HINT:
  
  For radiator with resin tanks, perform the water leak test after submerging the radiator in water and shaking it until all the bubbles are released. The bubbles are the result of air trapped in the clearance between the tank and lock plate.
INSTALL RADIATOR CAP SUB-ASSEMBLY