OEM 2002 Toyota Echo Radiator

2002 Toyota Echo Radiator Parts Q&A

• Q: How to remove and reinstall a radiator on 2002 Toyota Echo?

  A: The first step for radiator removal consists of draining the engine coolant followed by engine under cover removal. Disconnect the electric cooling fan connector together with the horn connector while also disassembling the upper and lower radiator hoses and radiator reservoir hose along with the 2 oil cooler hoses in automatic transmission models. The removal process begins with unclipping the 2 mounting brackets and radiator cover. After that, the technician should remove 7 (without A/C) or 9 (with A/C) bolts from the upper supports before extracting the radiator assembly accompanied by the 2 radiator support cushions and grommets. The electric cooling fan gets disconnected from the radiator through a three-bolt removal process. Radiator disassembly begins with drain plug removal together with its O-ring followed by disconnecting the No. 3 radiator hose and extracting 2 bolts and water filter from its place. Apply Special Service Tool: 09230-01010 by mounting its claw to the overhaul handle and set the stopper bolts to maintain a "B" dimension between 0.2 - 0.3 mm (0.008 - 0.012 inch). The same tool should be used to loosen the lock plates before gently tapping the radiator bracket for tank and O-ring removal. To service automatic transmission models start by removing the oil cooler from the lower tank through the process of undoing 2 nuts, 2 plate washers and then proceeding to remove the oil cooler and its 2 O-rings. The lock plate requires assessment for damage so any deformation needs correction because multiple recaulking will result in radiator replacement. New O-rings must be installed on the oil cooler before attaching it to the lower tank and tightening 2 plate washers followed by 2 nuts to 8.34 Nm (85 kgf-cm, 74 inch lbs.). Place new O-rings and tanks properly while checking that no foreign elements remain in the lock plate groove before gently tapping the lock plate with a soft mallet until gaps vanish. Adjust the stopper bolt of special assembly tool 09230-01010 and 09231-14010 to match 8.4 mm (0.331 inch) dimension "B" then complete lock plate caulk by avoiding contact with tank ribs or brackets and pipes. Examine the lock plate height after caulking to confirm it lies within 7.40 - 7.80 mm (0.2913 - 0.3071 inch). Screw in the water filter using two bolts while torquing them to 7.5 Nm before attaching the No. 3 radiator hose. Apply a new O-ring to the drain plug then fasten it into place. The water leak inspection requires the drain plug to be tightened along with plugging the inlet and outlet pipes with Special Service Tool: 09230-01010 and applying radiator cap tester pressure at 177 kPa (1.8 kgf/cm2, 26 psi) for leak detection by submerging the radiator in water. The electric cooling fan needs three bolts for attachment which require 7.5 Nm (80 kgf-cm, 66 inch lbs.) torque before installing the radiator assembly through its position of two radiator support cushions and grommets allowing grommet assembly to the body brackets followed by securing upper radiator supports with 7 (without A/C) or 9 (with A/C) bolts and next reconnecting upper and lower radiator hoses and radiator reservoir hose and for automatic transmission models the two oil cooler hoses. The installation process ends by attaching the radiator cover with 2 clips while reconnecting the horn and electric cooling fan connectors before placing the engine under covers and filling with engine coolant before starting the engine and checking for coolant leakage.