OEM 2004 Toyota Solara Radiator

2004 Toyota Solara Parts Questions & Experts Answers

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

  A: The radiator service requires removal of the drain plug and O-ring as the initial step. You should use Special Service Tool: 09230-01010 (09231-01010, 09231-01030) by placing the claw on the overhaul handle and setting the stopper bolt at dimension B between 0.2 to 0.3 mm (0.008 to 0.012 inch) to shield against damages. The tool that released the lock plate caulking should also remove the radiator bracket caulking before applying gentle hammer blows on the soft-faced hammer which will separate the upper and lower tanks and O-ring from their positions. The automatic transmission oil cooler assembly requires unmounting the cooler pipe and loose two plate washers and nuts before extracting the oil cooler through its two O-rings. Attach the oil cooler to its surrounding components through use of plate washers and nuts before applying torque to 8.3 Nm (85 kgf-cm, 73 inch lbs.) and continuing with the cooler pipe installation at a torque of 14.7 Nm (150 kgf-cm, 11 ft. lbs.). Check the lock plate for signs of damage together with the groove condition for correct reassembly and leak prevention; perform repairs when needed because the radiator limits its re-caULKing to two times before needing replacement. Replace the upper and lower radiator tanks with new O-rings then ensure the presence of no foreign objects and tap the lock plate to prevent gaps. Adjust stopper bolt on Special Service Tool: 09230-01010, 09231-14010 until it reaches dimension B of 8.4 mm (0.331 inch). Check the lock plate height (H) which should be between 7.40 to 7.80 mm (0.2913 to 0.3071 inch) after caulking it by applying pressure to the tool while avoiding contact with pipes and brackets. Adjust if needed. The drain plug installation process includes adding a new O-ring then securing it while testing for water leaks by using Special Service Tool: 09230-01010 to apply 177 kPa of pressure through the radiator cap tester while submerging the radiator in water. Verification occurs after swishing the radiator to release air.