Cooling System (Mechanical): Radiator: Reassembly

Inspect Lock Plate
Inspect the lock plate for damage.

Fig 1: Identifying Lock Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible.

NOTE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.
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.
  NOTE: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.
  
  Fig 2: Identifying Normal O-Ring
  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: Identifying Correct Method Of Tapping Lock Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Assemble SST
SST 09230-01010
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" shown in the diagram.
  Dimension "B": 8.4 mm (0.34 in.)
Caulk Lock Plate
1. Lightly press SST against the lock plate in the order shown in Fig 4. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper bolt.
  SST 09230-01010
  
  Fig 4: Assembling SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 5: Caulking Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not stake the areas protruding around the ports.
    
    Fig 6: Identifying Stake Areas Under Port
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - The points shown in the rib sides near here cannot be staked with SST. Use pliers or similar object and be careful not to damage the core plates.
  Fig 7: Staking Radiator Lock Plate With Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the lock plate height (H) after completing the caulking.
  
  Fig 8: Identifying Lock Plate Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Plate height (H): 7.4 - 7.8 mm (0.2959 - 0.3119 in.)
  
  If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
Paint Lock Plates
Install Drain Plug To Radiator
1. Install a new O-ring to the drain plug.
2. Apply soapy water to the O-ring.
3. Install the drain plug.
Check For Water Leaks
1. Using SST, plug the inlet and outlet pipes of the radiator.
  SST 09230-01010
  
  Fig 9: Plugging Inlet And Outlet Pipes Of Radiator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a radiator cap tester, apply pressure to the radiator.
  Test pressure: 177 kPa (1.8 kgf/cm ² , 26 psi)
3. Check for water leaks.
NOTE: On radiators with resin tanks, there is a clearance between the core plate and tank where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before performing the water leak test, first swirl the radiator around in the water until all air bubbles disappear.
Install Supports
Torque: 12.7 N.m (130 kgf.cm, 9 ft.lbf)
Install No.1 Fan Shroud