Reassembly

2AZ-FE COOLING: RADIATOR:

REASSEMBLY

1. INSTALL OIL COOLER ASSEMBLY (for Automatic Transaxle)





(a) Clean the O-ring contact surface of the lower tank and oil cooler.
(b) Install 2 new O-rings to the oil cooler.
(c) Install the oil cooler to the lower tank with the 2 plate washers and nuts.
Torque: 8.3 Nm (85 kgf-cm, 73 in-lbf)
(d) Install the cooler pipe in the direction indicated in the illustration.
Torque: 14.7 Nm (150 kgf-cm, 11 in-lbf)
2. INSTALL RADIATOR TANK UPPER AND TANK LOWER





(a) After checking that there are no foreign objects in the lock plate groove, install a new O-ring without twisting it.

HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.





(b) Install the tank without damaging the O-ring.
(c) Tap the lock plate with a soft-faced hammer so that there is no gap between the lock plate and the tank.
3. ASSEMBLY SST
SST: 09230-01010
SST: 09231-14010





(a) Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration.
(b) While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration.
Dimension B:
8.4 mm (0.331 in)
4. CAULK LOCK PLATE





(a) Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate.
SST: 09230-01010





(b) Check the pipes, brackets or tank ribs.

HINT: Do not tap the areas protruding around the pipes, brackets or tank ribs.





(c) Check the core plates.

HINT: The dotted circles shown in the illustration and parts of the oil cooler near the dotted circles (A/T) cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates.





(d) Check the lock plate height (H) after completing the caulking.
Plate height (H):
7.40 to 7.80 mm (0.2913 to 0.3071 in.)
If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
5. INSTALL DRAIN PLUG
(a) Install a new O-ring to the drain plug.
(b) Install the drain plug.