Overhaul

RADIATOR ASSEMBLY (2AZ-FE)
OVERHAUL
1. REMOVE RADIATOR DRAIN COCK PLUG
a. Remove the drain cock plug.
b. Remove the O-ring from the drain cock plug.





2. ASSEMBLE SST
SST 09230-01010 (09231-01010, 09231-01030)
a. Install the claw onto the overhaul handle by inserting it in the hole at part "A" as shown in the illustration.
b. While gripping the handle, adjust dimension B to between 0.2 and 0.3 mm, using the stopper bolt.
Dimension "B": 0.2 to 0.3 mm (0.008 to 0.012 inch)

NOTICE: If the stopper bolt is not adjusted, the claw may be damaged.





3. UNCAULK CORE PLATE
a. Straighten the core plate by gripping it with SST until stopped by the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01030)





4. REMOVE RADIATOR TANK UPPER
a. Lightly tap the bracket of the radiator tank (or radiator tank pipe) with a soft faced hammer to remove the radiator tank.
b. Remove the O-ring.
5. REMOVE RADIATOR TANK LOWER

HINT: Perform the same procedures as the radiator tank upper.





6. INSPECT RADIATOR CORE SUB-ASSEMBLY
Check the core plate for damage.

HINT:
- If the sides of the core plate groove are deformed, it is impossible to reassemble the radiator tank. Therefore, first correct any deformation using pliers or a similar tool.
- Water leakage will occur if the bottom of the core plate groove is damaged or dented. Repair or replace it if necessary.

NOTICE: The radiator can only be recaulked 2 times. After being recaulked 2 times, the radiator assembly must be replaced.





7. INSTALL RADIATOR TANK UPPER
a. Check that there are no foreign objects in the core plate groove, then install a new O-ring without twisting it.

HINT: To clean the core plate groove, lightly rub it with sandpaper with out scratching it.





b. Install the radiator tank without damaging the O-ring.
c. Tap the core plate with a soft faced hammer so that there is no gap between the core plate and radiator tank.
8. INSTALL RADIATOR TANK LOWER

HINT: Perform the same procedures as the radiator tank upper.





9. ASSEMBLE SST
SST 09230-01010 (09231-01010, 09231-01020)
a. Install the punch assembly into the overhaul handle by inserting it in the hole at part "A" as shown in the illustration.
b. 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 inch)





10. CAULK CORE PLATE
a. Lightly press SST against the core plate in the order shown in the illustration. After repeating this a few times, fully caulk the core plate by gripping the handle until stopped by the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01020)





HINT:
- Do not tap the areas protruding around the pipes, brackets or tank ribs.





- Do not tap the sections shown in the illustration or the oil collar using SST. Use pliers or a similar tool. Be careful not to damage the core plate.





b. Check the core plate height (H) after completing the caulking.
Plate height (H): 8.7 to 9.1 mm (0.343 to 0.358 inch)
If the height is not as specified, readjust the stopper bolt of the handle, then caulk again.
11. INSTALL RADIATOR DRAIN COCK PLUG
a. Install a new O-ring onto the drain cock plug.
b. Install the drain cock plug.