OEM 2003 Toyota Tundra Radiator

2003 Toyota Tundra Parts Questions & Experts Answers

• Q: How to service and repair the radiator on 2003 Toyota Tundra?

  A: The radiator repair process starts with unfastening four bolts and removing two pipes and bushings together with two supporting components. Remove both the radiator plug along with the drain cap before proceeding. Use Special Service Tool: 09230-01010 by fitting its claw section to the overhaul handle while adjusting the stopper bolt to maintain a dimension "B" measurement within 0.2 to 0.3 millimeter (0.008 to 0.012 inch) range to safeguard the claw components. Follow the same procedure with the tool for lock plate uncaulking until the handle stops against the stopper bolt. A soft-faced hammer will help extract the radiator port tank together with the O-ring when softly tapped. Automatic transmission requires the removal of two inlet pipes with two nuts and two plate washers and an oil cooler before extracting the two O-rings on the oil cooler. Attach the oil cooler to the lower tank using 2 new O-rings alongside 2 plate washers and 2 nuts where torquing should reach 8.3 Nm (85 kgf-cm, 74 inch lbs.). Finish the procedure by installing the 2 inlet pipes with torque set to 15 Nm (150 kgf-cm, 11 ft. lbs.). Check the lock plate for damage then adjust any deformation before reassembly to avoid water leakage as the radiator has a limited ability to be reconditioned twice before being replaced. Install replacement O-rings along with tanks then check that no foreign particles exist within the lock plate groove before using a soft-faced hammer for tapping the lock plate to remove any gaps. Adjust Stopper Bolt through Special Service Tools 09230-01010 and 09231-14010 to reach dimension "B" of 8.4 mm (0.34 inch). Press the tool against the lock plate to apply caulk while monitoring H dimension for proper height of 7.4 - 7.8 millimeters (0.2959 - 0.3119 inches) before adjusting as needed. Put a new O-ring to the drain plug followed by soapy water application before inserting the drain plug. The radiator cap tester (Special Service Tool: 09230-01010) will enable pressure testing at 147 kPa (1.5 kgf/cm2, 21 psi) on the inlet and outlet pipes after swirlishly washing out the air bubbles from the radiator. End the installation by mounting 2 radiator supports alongside 2 bushings and 2 pipes which need to be fastened with 4 bolts torqued to 12.7 Nm (130 kgf-cm, 9 ft. lbs.). Furthermore, replace the radiator cap.