Reassembly

3UZ-FE COOLING: RADIATOR: REASSEMBLY

REASSEMBLY

1. INSTALL OIL COOLER

(a) Install 2 new O-rings to the oil cooler.
(b) Install the oil cooler to the lower tank with the 2 plate washers and 2 nuts.
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)
(c) Install the 2 inlets.
Torque: 14.7 Nm (150 kgf-cm, 11 ft-lbf)
2. INSTALL RADIATOR TANK
(a) Check that the lock plate groove is free from foreign objects.
If necessary, clean the lock plate groove by lightly rubbing it with sandpaper.
NOTE:
Do not scratch the lock plate groove.

(b) Install a new O-ring.

(e) Tap the lock plate with a plastic-faced hammer so that there is no gap between the lock plate and the tank.
3. CAULK LOCK PLATE

(a) Install the punch assembly to part A of the overhaul handle as shown in the illustration.
SST: 09230-01010
SST: 09231-14010
(b) While gripping the handle, adjust the stopper bolt so that dimension B is as specified below.
Dimension B:
8.4 mm (0.33 in.)
(c) 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 bolt.

SST: 09230-01010
SST: 09231-14010
NOTICE:
- Do not press the protruding areas around the ports A, flange B and bracket C.

- Do not press the circled areas in the illustration. Use pliers and be careful not to damage the core plates.

(d) Check the lock plate height H after completing the caulking.
Plate height H:
8.8 mm (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.
4. INSTALL RADIATOR DRAIN COCK PLUG
(a) Install a new O-ring to the drain plug.
(b) Install the drain plug.
5. INSPECT WATER LEAK

(a) Plug the inlet and out let pipes of the radiator with SST.
SST: 09230-01010
(b) Using a radiator cap tester, apply pressure to the radiator.
Test pressure:
177 kPa (1.8 kgf/cm2, 26 psi)
(c) Submerge the radiator in water.

(d) Inspect for leaks.
HINT: For radiator with resin tanks, perform the water leak test after submerging the radiator in water and shaking it until all the bubbles are released. The bubbles are the result of air trapped in the clearance between the tank and lock plate.

6. INSTALL STRAIGHT SCREW PLUG
(a) Install the straight screw plug.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
HINT:
- When reusing the plug, inspect the O-ring.
- If the O-ring has scratches of cuts, replace the straight screw plug.

7. INSTALL RADIATOR CAP SUB-ASSEMBLY
8. INSTALL PACKING