Section 528 (Radiator): Radiator: Reassembly

WARNING: This page is about a different car, the 2003 Lexus IS 300. However, it is still accessible from the selected car via links, so may be relevant.

A/T:
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.
  Torque: 8.3 N.m (85 kgf.cm, 74 in.lbf)
3. Install the cooler pipes in the direction indicated in the illustration.
  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
INSPECT LOCK PLATE FOR DAMAGE
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.
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 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-Rings And Tanks
  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: Install Tank Without Damaging The O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ASSEMBLE SST
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 the illustration.
2. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration.
  Dimension B: 8.4 mm (0.331 in.)
Fig 4: Installing Punch Assembly To Overhaul Handle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CAULK LOCK PLATE
1. 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 plate.
  SST 09230-01010
  
  Fig 5: Installing Caulk 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: Identifying Areas To Not Stake Which Protrude Around Ports
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - The points shown in the illustration cannot be staked with the SST. Use pliers or similar object and be careful not to damage the core plates.
  Fig 7: Identifying Points Which Cannot Be Staked With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the lock plate height (H) after completing the caulking.
  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.
INSTALL ECT SWITCH
1. Install a new O-ring to the ECT switch.
2. Install the ECT switch.
INSTALL DRAIN PLUG
1. Install a new O-ring to the drain plug.
2. Install the drain plug.
INSPECT FOR WATER LEAKS
1. Tighten the drain plug.
2. Plug the inlet pipes of the radiator with SST.
  SST 09230-01010
3. Using a radiator cap tester, apply pressure to the radiator.
  Test pressure: 177 kPa (1.8 kgf/cm ² , 26 psi)
4. Submerge the radiator in water.
  
  Fig 9: Using Radiator Cap Tester To Apply Pressure To Radiator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.