Section 11 (Engine Cooling System (1GR-FE)): Radiator: Reassembly

WARNING: This page is about a different car, the 2007 Toyota Tacoma. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL RADIATOR TANK UPPER
1. Install the new radiator tank.
2. Tap the core plate with a soft-faced hammer until there is no gap between the core plate and radiator tank.
  
  Fig 1: Installing Radiator Tank Upper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR TANK LOWER
HINT:

Perform the same procedures as for the radiator tank upper.
ASSEMBLE SST
SST 09230-01010 (09231-01010, 09231-01020)
1. Install the punch assembly into the overhaul handle by inserting it into the hole in part A as shown in Fig 2.
2. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in Fig 2.
  Dimension B: 8.4 mm (0.331 in.)
  
  Fig 2: Assembling SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CAULK CORE PLATE
1. Lightly press SST against the core plate in the order shown in Fig 3. 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 Fig 4 or the oil collar using SST. Use pliers or a similar tool.
  
  Be careful not to damage the core plate.
  
  Fig 3: Pressing SST Against Core Plate In Order
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 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.
  
  Fig 4: Checking Core Plate Height
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR DRAIN COCK
1. Install a new O-ring onto the drain cock plug.
2. Install the drain cock plug.