Reassembly

1GR-FE COOLING: RADIATOR: REASSEMBLY

1. INSTALL RADIATOR TANK UPPER





(a) Install the new radiator tank.

(b) Tap the core plate with a soft-faced hammer until there is no gap between the core plate and radiator tank.

2. INSTALL RADIATOR TANK LOWER

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

3. ASSEMBLE SST





SST : 09230-01010

09231-01010

09231-01020

(a) Install the punch assembly into the overhaul handle by inserting it into the hole in 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 in.)

4. 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 portions indicated in the illustration or the oil cooler 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 in.)

If the height is not as specified, readjust the stopper bolt of the handle, then caulk it again.

5. INSTALL RADIATOR DRAIN COCK

(a) Install a new O-ring onto the drain cock plug.

(b) Install the drain cock plug.