OEM 2002 Toyota Corolla Radiator

2002 Toyota Corolla Parts Questions & Experts Answers

• Q: How to service and repair the radiator on 2002 Toyota Corolla?

  A: The radiator service and repair process starts by draining engine coolant which requires removing engine under covers. Disconnection of electric cooling fan connectors no. 1 and no. 2 along with upper and lower radiator hoses and radiator reservoir hose should be followed by extractions of oil cooler hoses for automatic transmission models. The service begins with removing the upper radiator supports' 2 bolts then taking off the radiator assembly and finally eliminating the 2 lower radiator supports. Unplug the electric cooling fan from the radiator through the removal of all 5 bolts. During disassembly remove the drain plug with its O-ring but use Special Service Tool: 09230-01010 to assemble the stopper bolts for dimension "B" at 0.2 - 0.3 mm (0.008 - 0.012 inch) to defend the claw from damage. The tool works for decalking lock plates when you operate the handle until the stopper bolts stop its movement. A soft-faced hammer should be used to knock off tanks and O-rings from the radiator bracket. Automatic transmission models require removal of the lower tank oil cooler by undoing 2 nuts and 2 plate washers before removing the oil cooler and 2 O-rings. Examine the lock plate for damage then repair any deformations because only two radiator caulk applications are possible before replacement is necessary. To reassemble the system first set in place two fresh O-rings on the oil cooler then mount it onto the lower tank and fasten it using two plate washers and two nuts before torquing the nuts to 8.34 Nm (85 kgf-cm, 74 inch lbs.). New O-rings and tanks should be installed onto their respective positions and the lock plate groove must remain empty of foreign objects before the plate gets tapped with a soft-faced hammer to minimize gaps. Use Special Service Tools 09230-01010 and 09231-14010 to adjust the stopper bolt for a setting of 8.4 mm (0.331 inch) dimension "B.". Caulk the lock plate lightly with the tool while keeping away from pipes and tank ribs and check the lock plate height (H) to stay within 7.40 - 7.80 mm (0.2913 - 0.3071 inch). Next apply a fresh O-ring onto the drain plug before installing the drain plug. The examination for water Leakage requires users to use Special Service Tool: 09230-01010 to close off pipes and use a radiator cap tester at 26 psi (1.8 kgf/cm2, 177 kPa) to test for leaks before soaking the radiator in water to check for losses while continuously stirring the container to erase air bubbles. Installation includes attaching the electric cooling fan with 5 bolts and torquing them to 6 Nm (60 kgf-cm, 53 inch lbs.) then installing the radiator assembly by attaching 2 lower radiator supports to the radiator and body brackets followed by using 2 bolts to secure the upper radiator supports while ensuring rubber cushion (A) remains uncompressed. The A/C condenser must be mounted with 4 bolts then radiator hoses including upper and lower systems and radiator reservoir hose must be connected and automatic transmissions models should receive dual oil cooler hoses installation. The procedure ends by reconnecting both electric cooling fan connectors No.1 and No.2 and reinstalling the engine under covers before filling with engine coolant and starting the engine to check for any coolant leaks.