Toyota 16400-0F060
Radiator Assembly

First, inspect the lock plate groove for foreign materials then install a new O-ring correctly without twisting it and use sandpaper to clean the groove lightly. The installation of the tank requires special attention to protect the O-ring from damage while tapping the lock plate with a plastic-faced hammer should remove all gaps between the tank and the lock plate. Secure Special Service Tool: 09230-01010 by fitting its punch assembly into part A of the overhaul handle and set the stopper bolt using handle grip to measure B as 8.4 mm (0.331 in.). Follow the illustration to use Special Service Tool: 09230-01010 by pressing it against the lock plate while focusing on the non-protruding parts around the ports and brackets. Pliers need to be used for the marked areas in the illustration. Inspect the lock plate height H after caulking because it must measure 8.8 mm (0.346 in.). Adjust as needed if necessary. The radiator drain plug requires a new O-ring installation before being attached through its drain hole. The inspection for radiator leaks begins by using Special Service Tool: 09230-01010 to seal the inlet and outlet ports followed by testing with a standard 177 kPa (1.8 kgf/cm2, 26 psi) pressure from a radiator cap tester while submerging the unit in water and checking for leaks by shaking the radiator to release trapped air. Fit the radiator bracket sub-assembly through installing two brackets using four bolts which need to be tightened to 133 kgf-cm (13 Nm, 10 ft-lbf).

Take out the 4 bolts and the radiator.

Remove the 4 nuts of the fluid coupling fan and take off the fan shroud along with the fluid coupling fan, ensuring not to damage the radiator core.

Install the radiator with the 4 bolts, torquing to 18 N*m (184 kgf*cm, 13 ft.*lbf).

Drain the engine coolant.

Use the tool to uncaulk the lock plate by squeezing the handle until it is stopped by the stopper bolt.