Section 8 (Engine Cooling System): Radiator: Reassembly

WARNING: This page is about a different car, the 2006 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL NEW O-RING AND TANK
1. Check that there are no foreign objects in the lock plate groove, and install a new O-ring. Make sure the O-ring is not twisted.
  HINT:
  
  When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it.
  
  Fig 1: Installing New O-Ring And Making Sure O-Ring Is Not Twisted
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the tank without damaging the O-ring.
3. Tap the lock plate with a plastic-faced hammer so that there is no gap between the lock plate and the tank.
  
  Fig 2: Tapping Lock Plate With Plastic-Faced Hammer So There Is No Gap Between Lock Plate And Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the punch assembly to part A of the overhaul handle as shown.
  SST 09230-01010 (09231-01010, 09231-01020)
  
  Fig 3: Installing Punch Assembly To Part A Of Overhaul Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. While gripping the handle, adjust the stopper bolt so that dimension B is as specified below.
  Dimension B: 8.4 mm (0.331 in.)
CAULK LOCK PLATE
1. Lightly press SST against the lock plate in the order shown. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper bolt.
  SST 09230-01010 (09231-01010, 09231-01020)
  
  Fig 4: Lightly Pressing SST Against Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not press the protruding areas around the ports A and bracket B.
    
    Fig 5: Caution For Do Not Press Protruding Areas Around Ports & Bracket
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Do not use SST to press the areas indicated by the circle marks. Use pliers and be careful not to damage the core plates.
    
    Fig 6: Caution For Do Not Use SST To Press Areas Indicated
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the lock plate height H after completing the caulking.
  Plate height H: 8.8 m (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 7: Checking Lock Plate Height H After Completing The Caulking
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRAIN PLUG
1. Install a new O-ring to the drain plug.
2. Install the drain plug.
INSPECT FOR WATER LEAKS
1. Plug the inlet and outlet pipes of the radiator with SST.
  SST 09230-01010
  
  Fig 8: Plugging Inlet And Outlet Pipes Of Radiator With SST
  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. Submerge the radiator in water.
4. Inspect for leaks.
  HINT:
  
  On radiators with resin tanks, there is clearance between the tank and lock plate where a small amount of air will remain. This air is released when the radiator is submerged in water, giving the appearance of an air leak. Before performing the water leak test, first shake the radiator in the water until all air bubbles are released.
  
  Fig 9: Inspecting For Radiator Leak
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SIDE SUPPORT
1. Install the 2 side supports with the 8 nuts.
  Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf)
2. Install the 2 brackets with the 4 nuts.
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)