Toyota 16410-0C190
Radiator

You can start radiator assembly (2TR-FE) overhaul by dismantling the drain cock components which include remover of the drain cock plug and O-ring. Adjust Special Service Tools: 09230-01010, 09231-01010, 09231-01030 through the claw connection to the overhaul handle while using the stopper bolt to achieve 0.2-0.3 mm dimension B without harming the claw components. Straighten the core plate by using the same Special Service Tool which will stop when reaching the stopper bolt position. Use a soft-faced hammer to tap the radiator tank bracket until removal of the radiator tank upper and then repeat the same process for the radiator tank lower. Examine the radiator core sub-assembly for damage then repair or replace the core plate when the bottom groove shows damage yet know that the radiator must be replaced after two caulkings. Tapping the core plate leads to the installment of a new radiator tank upper until it establishes a perfect fit followed by installation of the radiator tank lower. Use Special Service Tool: 09230-01010 (09231-01010, 09231-01020) to insert the punch assembly into the overhaul handle and set dimension B to 8.4 mm. Perform core plate caulking by applying gentle pressure with the tool in the correct order but avoid striking designated areas and the oil cooler. Verify the core plate height (H) which ideally ranges from 8.7 to 9.1 mm and perform adjustments if needed. Reinstall the drain cock plug after fitting a fresh O-ring onto its plug.

Start radiator replacement by extracting the drain cock plug from its position before you remove the O-ring attached to it. Adjust part B of Special Service Tool: 09230-01010, 09231-01010, 09231-01030 using the stopper bolt to a 0.2 to 0.3 mm range by inserting the overhaul handle-claw assembly into the part A hole while ensuring the claw remains intact if the stopper bolt adjustment is impossible. Connect the core plate to Special Service Tool: 09230-01010, 09231-01010, 09231-01030 to remove its caulk. Continue operating the tool until the stopper bolt creates full resistance. Light taps from a soft-faced hammer let you detach both the radiator tank bracket and the radiator tank pipe. The radiator tank lower requires the exact same procedure that was used for the radiator tank upper.

The radiator should be placed back with the 4 bolts, torqued to 18 Nm (184 kgf-cm, 13 ft. lbs.).

Install the fan shroud and fan with fluid coupling together, ensuring no contact with the radiator.

Add engine coolant, check for engine coolant leakage, and install the engine under cover sub-assembly No.1 with the 4 bolts torqued to 30 Nm (306 kgf-cm, 22 ft. lbs.).

Install the fan pulley, then the fan shroud and fan with fluid coupling, ensuring they do not contact the radiator.

Install the engine under cover sub-assembly NO.1 for Pre Runner and 4WD Type, torqued to 30 Nm (306 kgf-cm, 22 ft-lbf).