Toyota 16400-22170
Radiator Assembly

Start radiator servicing by gripping and removing the radiator drain cock plug while extracting its O-ring. Install the claw of Special Service Tool: 09230-01010 (09231-01010, 09231-01030) on the overhaul handle while adjusting dimension B to the range of 0.2 to 0.3 mm using the stopper bolt to protect the claw from damage. The core plate receives treatment through straightening using the same tool until the stopper bolt terminates the process. Start faucet drain removal that clears the radiator tanks one by one through targeted light hammer tapping at their brackets followed by O-ring removal from each side. Examine the radiator core sub-assembly for damage by using pliers to fix any core plate groove deformed areas and note that replacement will be necessary if bottom damage occurs due to its two permitted recaulking operations before necessary change of unit. The left radiator tank installation should begin with a check for foreign objects in the core plate groove followed by addition of the new O-ring which must be untwisted before installing tank placement and final tapping to reduce gaps. Repetition occurs for the installation of the right radiator tank. To perform the core plate caulking process, use Special Service Tool: 09230-01010 (09231-01010, 09231-01020). Insert the punch assembly into the overhaul handle and adjust the stopper bolt until the dimension B measures 8.4 mm. After installing a new O-ring onto the drain cock plug users should install the plug.

Begin radiator installation by attaching the fan shroud assembly through tightening the 2 pawl fittings and then install the fan assembly by using 2 bolts secured at 5.0 Nm (51 kgf-cm, 44 in-lbf). Start by installing the lower support for the radiator followed by the assembly installation that requires two uppers and two bolts to be tightened at 19 Nm (194 kgf-cm, 14 ft-lbf). Complete installation requires hooking up the radiator reservoir hose and connecting two clamps on the engine room main wire and attaching two connectors to the cooling fan motor. The technical procedure requires connections between the No. 1 oil cooler outlet tube and inlet tube along with the radiator hose outlet and inlet. Affix the engine coolant before you attach the negative battery terminal cable. After reconnecting the cable from the negative (-) battery terminal you should check for engine coolant leakage and initialize the systems which require this step. Installation of the engine under the right-hand (RH) engine cover completes the procedure.

Disconnect the 2 cooling fan motor connectors, the 2 clamps of the engine room main wire, and the radiator reservoir hose, then remove the 2 bolts and 2 radiator support uppers.

Caulk the core plate by lightly pressing Special Service Tool: 09230-01010 against it in the specified order, fully caulking by gripping the handle until stopped by the stopper bolt, while avoiding tapping around the pipes, brackets, or tank ribs, and using pliers for any sections shown in the illustration.

Install the radiator support lower.

Wet the relief valve and pressure valve with engine coolant or water, keeping the tester at an angle of 30 degrees or more above the horizontal.

Assemble Special Service Tool: 09230-01010 (09231-01010, 09231-01020) by inserting the punch assembly into the overhaul handle and adjusting the stopper bolt to set dimension B to 8.4 mm.

Connect the cable to the negative battery terminal.