OEM 2002 Toyota Tundra Radiator

2002 Toyota Tundra Parts Questions & Experts Answers

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

  A: Begin radiator removal by taking out the under engine cover then drain coolant before exploiting the radiator reservoir hose together with both radiator hoses from the unit. The radiator requires disconnection of automatic transmission oil cooler hoses for vehicles equipped with automatic transmission models. Second, detach the No. 2 fan shroud by removing its 2 clips preceding the removal of the radiator assembly using 4 bolts. The next step involves removing the No. 1 fan shroud through dissolution of its 4 bolts. Disassemble the radiator by unfastening 4 bolts alongside 2 pipes and 2 bushings and 2 radiator supports until the radiator cap together with the drain plug can be removed. Use Assembly Special Service Tool: 09230-01010 with the claw fastened to the overhaul handle after setting the stopper bolt to obtain a stopper width between 0.2-0.3 mm (0.008-0.012 inches) to prevent claw damage. Use the same tool to uncaulk lock plates which subsequently permits removal of tanks and O-rings through tapping on the radiator port with a soft-faced hammer. The procedure for automatic transmission involves removing the oil cooler from the lower tank through extraction of two inlet pipes, two nuts, and two plate washers. Workers should also remove the two O-rings from the oil cooler. Attach the lower tank oil cooler by cleaning contact surfaces first before inserting new O-rings then adding two plate washers and two nuts which should be tightened to 8.3 Nm (85 kgf-cm, 74 inch lbs.) and finally securing the two inlet pipes with 15 Nm (150 kgf-cm, 11 ft. lbs.). Perform a review of the lock plate to detect any damage and use needed repairs to achieve correct reinstallation. Use new O-rings for the installation while inspecting the lock plate gaps with a soft-faced hammer until they disappear. Adjust the stopper bolt of Special Service Tool: 09230-01010 and 09231-14010 until it reaches dimension "B" at 8.4 mm (0.34 inch) then subject the lock plate to caulk by pressing the tool onto it. Verify the lock plate height falls within 7.4-7.8 mm (0.2959-0.3119 inch). Fitting a brand new O-ring to the drain plug requires soapy water application before reinstallation of the drain plug. Use Special Service Tool: 09230-01010 while plugging inlet and outlet pipes and apply pressure of 147 kPa (1.5 kgf/cm2, 21 psi) for checking water leaks using a radiator cap tester. Affix the radiator supports, bushings, and pipes with 4 bolts that require a torque value at 12.7 Nm (130 kgf-cm, 9 ft. lbs.) before installing the radiator cap. Initiate with the No. 1 fan shroud by attaching 4 bolts that need 5 Nm (50 kgf-cm, 44 inch lbs.) torque before positioning the radiator assembly onto the radiator support holes with 4 bolts secured at 12 Nm (120 Nm, 9 ft. lbs.). Reinstall the A/T oil cooler hoses and both radiator hoses, reservoir hose and the No. 2 fan shroud with its retaining clips. After filling with engine coolant the technician should start the engine for leak inspection followed by repeated coolant checks. The engine under cover installation completes operations.