OEM 2004 Toyota Echo Radiator

2004 Toyota Echo Parts Questions & Experts Answers

• Q: How to service and repair the radiator on 2004 Toyota Echo?

  A: Service of the radiator requires first draining the radiator fluid by unthreading the drain plug and removing the O-rings before disconnecting the No. 3 radiator hose and removing the water filter secured by 2 bolts. For installation of the claw onto the overhaul handle through Special Service Tool: 09230-01010 adjust dimension "B" to 0.2 - 0.3 mm (0.008 - 0.012 inch) to avoid damage. The lock plates should be uncaulked with the same tool while squeezing the handle until the stopper bolts activate and performing a gentle tap on the radiator bracket to disengage the tanks and O-rings. The automatic transmission requires removal of its lower tank oil cooler by disassembling 2 nuts and 2 plate washers followed by oil cooler and 2 O-ring extraction. Inspection of the lock plate should confirm any damage exists before making necessary repairs so the radiator can be recaulked up to two times before reaching replacement criteria. Put 2 new O-rings on the oil cooler then fasten it to the lower tank using 2 plate washers and 2 nuts while torquing them to 8.34 Nm (85 kgf-cm, 74 inch lbs.). Apply new O-rings onto the tanks after verifying the lock plate groove contains no foreign material and use a soft mallet to strike the lock plate until all gaps vanish. Special Service Tools 09230-01010 and 09231-14010 are used to assemble the system while adjusting the stopper bolt to reach an 8.4 mm (0.331 inch) measurement. Use the tool to press and caulk the lock plate while observing that no staking occurs near pipes or brackets and checking that the lock plate height falls within 7.40 - 7.80 mm (0.2913 - 0.3071 inch). Reinstall the water filter through two bolts secured at 7.5 Nm (76 kgf-cm, 66 inch lbs.) and attach the No. 3 radiator hose while installing a new O-ring on the drain plug then tightening it. Application of Special Service Tool: 09230-01010 with a test pressure of 177 kPa (1.8 kgf/cm2, 26 psi) helps reveal leaks by plugging the inlet and outlet pipes and submerged testing of the radiator in water. Resin tank radiators may retain a small amount of air at this stage.