Section 9 (Cooling (2GR-FSE)): Radiator: Reassembly

WARNING: This page is about a different car, the 2006 Lexus IS 350. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL RADIATOR UPPER TANK AND LOWER TANK
1. Check that there are no foreign objects in the lock plate groove, and install a new O-ring. Make sure that the O-ring is not twisted.
  HINT:
  
  When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it.
  
  Fig 1: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tap the lock plate with a plastic hammer so that there is no gap between the lock plate and tank.
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.)
CAULK LOCK PLATE
SST 09230-01010

Fig 2: Installing Punch Assembly To Overhaul Handle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 it is stopped by the stopper bolt.
  
  Fig 3: Pressing Lock Plate Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Do not tap the areas protruding around ports (1), claws (2) and grooves (3).
  
  Fig 4: Identifying Protruding Around Ports, Claws And Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. The points shown in the illustration cannot be tapped with SST. Use pliers and be careful not to damage the core plates.
  
  Fig 5: Identifying Pliers For Safety Of Core Plates
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check lock plate height (H) after completing caulking.
CHECK FOR WATER LEAKS
SST 09230-01010

Fig 6: Checking Lock Plate Height
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Plug the inlet and outlet pipes of the radiator with SST.
2. Using a radiator cap tester, apply pressure to the radiator.
  Test pressure: 177 kPa (1.8 kgf*cm ² , 26 psi)
  
  NOTE: Do not apply more than 177 kpa (1.8 kgf*cm² , 26 psi) to the radiator.
  
  Fig 7: Plugging Inlet And Outlet Pipes Of Radiator Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Submerge the radiator in water.
4. Check 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. Before doing the water leak test, first shake the radiator in the water until air bubbles disappear.
  
  Fig 8: Checking For Leaks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002