Overhaul

RADIATOR ASSEMBLY (2TR-FE)








COMPONENTS

OVERHAUL
1. REMOVE RADIATOR DRAIN COCK
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. Engage the claw with the overhaul handle by inserting it into the hole in 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 can not be 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 radiator tank bracket (or radiator tank pipe) with a soft-faced hammer to remove the radiator tank.
5. REMOVE RADIATOR TANK LOWER

HINT: Perform the same procedures as for 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 the core plate if necessary.

NOTICE: The radiator can only be caulked twice. After being caulked twice, the radiator assembly must be replaced.





7. 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.
8. INSTALL RADIATOR TANK LOWER

HINT: Perform the same procedures as for 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 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 inch)





10. CAULK CORE PLATE
a. Gently 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 dam age 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 it again.
11. INSTALL RADIATOR DRAIN COCK
a. Install a new O-ring onto the drain cock plug.
b. Install the drain cock plug.