Section 15 (Cooling System (Service Information)): Radiator: Reassembly: Reassembly

WARNING: This page is about a different car, the 2011 Toyota Avalon. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL OIL COOLER ASSEMBLY
1. Clean the O-rings contact surface of the lower tank and oil cooler.
  
  Fig 1: Installing Oil Cooler Assembly Components
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install 2 new O-rings to the oil cooler.
3. Install the oil cooler to the lower tank.
4. Install the plate washer and nut.
  Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf)
5. Install the cooler pipe.
  Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf)
6. Install the screw.
INSTALL RADIATOR TANK UPPER AND TANK LOWER
1. After checking that there are no foreign objects in the lock plate groove, install a new O-ring without twisting it.
  
  Fig 2: Installing New O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.
2. Install the tank without damaging the O-ring.
  
  Fig 3: Tapping Lock Plate With Soft-Faced Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tap the lock plate with a soft-faced hammer so that there is no gap between the lock plate and the tank.
ASSEMBLE SST
- SST: 09230-01010
- SST: 09231-14010
1. Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration.
  
  Fig 4: Installing Punch Assembly To Overhaul Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.)
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 gripping the handle until stopped by the stopper plate.
  
  Fig 5: Pressing SST Against Lock Plate In Specified Order
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09230-01010
  HINT:
  - Do not tap the areas protruding around the pipes, brackets or tank ribs.
  - The dotted circles shown in the illustration and parts of the oil cooler near the dotted circles cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates.
2. Check the lock plate height (H) after completing the caulking.
  
  Fig 6: Measuring Plate Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Plate height (H)
  
  7.40 to 7.80 mm (0.2913 to 0.3071 in.)
  
  If not within the specified height, adjust the stopper bolt of the handle and caulk again.
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.
  
  Fig 7: Plugging Inlet And Outlet Pipes Of Radiator With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09230-01010
2. Using a radiator cap tester, apply pressure to the radiator.
  Test pressure
  
  177 kPa (1.8 kgf/cm² , 26 psi)
3. Submerge the radiator in water.
4. Inspect for leaks.
  
  Fig 8: Inspecting Radiator For Leaks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  On radiators with resin tanks, there is 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.