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HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 648 (ENGINE COOLING SYSTEM (1MZ-FE/3MZ-FE))RADIATOR ASSEMBLYOVERHAUL

2004 Toyota Matrix XR, FWD, Standard

Radiator Assembly: Overhaul

2004 Toyota Matrix XR, FWD, StandardSECTION Overhaul

WARNING: This page is about a different car, the 2004 Toyota Camry. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE DRAIN PLUG
1. Remove the drain plug.
2. Remove the O-ring.
ASSEMBLE SST
SST 09230-01010 (09231-01010, 09231-01030)
1. Install the claw to the overhaul handle, inserting it in the hole in part "A" as shown.
2. While gripping the handle, adjust the stopper bolt so that dimension "B" is as shown.
  
  Fig 1: Assembling SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Dimension: 0.2 to 0.3 mm (0.008 to 0.012 in.)
NOTE: If the stopper bolt is not adjusted, the claw may be damaged.
REMOVE UNCAULK LOCK PLATE
Using SST to release the caulking, grip the handle until stopped by the stopper bolt.

SST 09230-01010 (09231-01010, 09231-01030)

Fig 2: Removing Uncaulk Lock Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RADIATOR TANK UPPER AND TANK LOWER
1. Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft-faced hammer and remove the tank.
2. Remove the O-ring.
  
  Fig 3: Removing Radiator Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL COOLER ASSY
1. Remove the screw and pipe.
2. Remove the nut and plate washer.
3. Remove the oil cooler.
4. Remove the 2 O-rings from the oil cooler.
  
  Fig 4: Removing Oil Cooler Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL COOLER ASSY
1. Clean the O-ring contact surface of the lower tank and oil cooler.
2. Install 2 new O-rings (1) to the oil cooler (2).
3. Install the oil cooler to the lower tank (3).
4. Install the plate washer (4) and nut (5).
  Torque: 8.3 N.m (85 kgf.cm, 73 in.lbf)
5. Install the pipe (6).
  Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf)
6. Install the screw (7).
  
  Fig 5: Installing Oil Cooler Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT LOCK PLATE FOR DAMAGE
Inspect the lock plate for damage.

HINT:
- If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible.
  Therefore, first correct any deformation with pliers or similar object.
- Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace if necessary.
  
  Fig 6: Identifying Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.
INSTALL RADIATOR TANK UPPER AND TANK LOWER
1. 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.
  
  Fig 7: Precautions For Installing O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the tank without damaging the O-ring.
3. Tap the lock plate with a soft-faced hammer so that there is no gap between the lock plate and the tank.
  
  Fig 8: Taping Lock Plate Using Soft-Faced Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ASSEMBLE SST
SST 09230-01010, 09231-14010
1. Install the punch assembly to the overhaul handle, inserting it in the hole in part "A" as shown.
2. While gripping the handle, adjust the stopper bolt so that dimension "B" shown.
  Dimension "B": 8.4 mm (0.331 in.)
  
  Fig 9: Assembling SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CAULK LOCK PLATE
1. Lightly press SST against the lock plate in the order shown. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate.
  SST 09230-01010
  
  Fig 10: Pressing SST Against Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - Do not tap the areas protruding around the pipes, brackets or tank ribs.
    
    Fig 11: Identifying Brackets And Tank Ribs
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - The points shown in the illustration and oil cooler near here cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates.
    
    Fig 12: Tweaking Bracket Using Pliers
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 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.

Fig 13: Identifying Lock Plate Height After Caulking
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRAIN PLUG
1. Install a new O-ring to the drain plug.
2. Install the drain plug.
INSPECT FOR WATER LEAKS
1. Plug the inlet and outlet pipes of the radiator with SST.
  SST 09230-01010
  
  Fig 14: Plugging Radiator Inlet And Outlet Pipes Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a radiator cap tester, apply pressure to the radiator.
  Test pressure: 177 kPa (1.8 kgf/cm ² , 26 psi)
3. Submerge the radiator in water.
4. Inspect for leaks.
HINT:

On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before doing the water leak test, first swish the radiator around in the water until all air bubbles disappear.

Fig 15: Inspecting Radiator For Leaks
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002