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CO-20
COOLING (5VZ-FE) - RADIATOR
CO013-02
Lock Plate REASSEMBLY
Lock Plate 1. INSPECT LOCK PLATE
Inspect the lock plate for damage.
HINT:
If the sides of the lock plate groove are deformed, reassembly
of the tank will be impossible.
NOTICE:
Core
The radiator can only be recaulked 2 times.
CO1267
After the 2nd time, the radiator core must be replaced.
2. INSTALL NEW O-RINGS AND TANKS
(a) After checking that there are no foreign objects in the lock
plate groove, install the new O-ring without twisting it.
HINT:
f Normal X Twisted
When cleaning the lock plate groove, lightly rub it with sand pa-
per without scratching it.
O-Ring X Twisted
CO0317
(b) Install the tank without damaging the O-ring.
CORRECT (c) Tap the lock plate with a soft-faced hammer so that there
is no gap between it and the tank.
Tank
WRONG
Tap
Lock
Plate
S02343
3. ASSEMBLE SST
Part "A" SST 09230-01010
(a) Install the punch assembly to the overhaul handle, insert-
ing it in the hole in part "A" as shown in the illustration.
Dimension "B" SST (b) While gripping the handle, adjust the stopper bolt so that
Stopper Bolt dimension "B" shown in the diagram.
Dimension "B": 8.4 mm (0.34 in.)
Punch Assembly Overhaul Handle CO1206
2002 4RUNNER (RM887U)
Author : Date : 1004
CO-21
COOLING (5VZ-FE) - RADIATOR
4. CAULK LOCK PLATE
5 3 7 (a) Lightly press SST against the lock plate in the order
shown in the illustration. After repeating this a few times,
1 2 fully caulk the lock plate by squeezing the handle until
stopped by the stopper bolt.
6 4 8
SST 09230-01010
SST
Stopper
Bolt Tank
Lock
Plate
Z17518
HINT:
Port
S Do not stake the areas protruding around the ports.
S02346
S The points shown in the rib sides near here cannot be
staked with SST. Use pliers or similar object and be care-
ful not to damage the core plates.
Z17605
(b) Check the lock plate height (H) after completing the caulk-
ing.
Plate height (H): 7.4 - 7.8 mm (0.2959 - 0.3119 in.)
If not within the specified height, adjust the stopper bolt of the
handle again and caulk again.
5. PAINT LOCK PLATES
H
6. INSTALL DRAIN PLUG TO RADIATOR
(a) Install a new O-ring to the drain plug.
S02349 (b) Apply soapy water to the O-ring.
(c) Install the drain plug.
2002 4RUNNER (RM887U)
Author : Date : 1005
CO-22
COOLING (5VZ-FE) - RADIATOR
7. CHECK FOR WATER LEAKS
SST
(a) Using SST, plug the inlet and outlet pipes of the radiator.
SST 09230-01010
(b) Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi)
S02350
(c) Check for water leaks.
Tank
HINT:
On radiators with resin tanks, there is a clearance between the
core plate and tank where a minute amount of air will remain,
giving the appearance of an air leak when the radiator is sub-
Lock
Plate merged in water. Therefore, before performing the water leak
test, first swirl the radiator around in the water until all air
O-Ring bubbles disappear.
P23709 8. INSTALL SUPPORTS
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