Radiator problem

Tiny
AMIR JOSEPH EL GAMAL
  • MEMBER
  • 2000 TOYOTA COROLLA
  • 1.3L
  • 4 CYL
  • 2WD
  • MANUAL
  • 110,000 MILES
Hi, last April I had a leak in the cooling system and it was the radiator and I replaced it with a brand new one.
Last week I noticed that the new radiator is leaking from the same exact area (as shown in the image)
I was thinking of two options:
1- Open the tank clean the gasket and then putting silicone (gasket maker) and reinstall the gasket, put another layer of silicone and reinstall the tank.
2- Remove the plastic tank and weld an aluminium or copper tank.
PS. I cannot buy another radiator because where I live, car parts are very very expensive.
Thanks
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Thursday, October 11th, 2018 AT 12:17 PM

3 Replies

Tiny
JACOBANDNICKOLAS
  • EXPERT
Hi and thanks for using 2CarPros. Com.

For some reason, the image did not upload. If you are referring to the plastic tanks on the sides or the radiator, they are non repairable. When the radiator is manufactured, the tanks, cooling fins and cooling tubes are crimped together. If you remove the tank and use a sealer, it will not hold the pressure. As far as replacing them with steel tanks. I have never seen it done and honestly, you would have so many joints to solder, there would most likely be a leak. Keep in mind, the tanks would need to have the outlets in the correct places. Plus, and I do not know if this pertains to your vehicle, but some of these vehicles had an engine oil cooler at the bottom of the radiator.

I am not sure where you are located, but trying to repair this type of problem may lead to bigger expenses.

Let me know if you have questions or need help with anything.

Take care,
Joe
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Thursday, October 11th, 2018 AT 6:37 PM
Tiny
AMIR JOSEPH EL GAMAL
  • MEMBER
Thanks Joe for your reply
So I do not have any other option rather than buying a new one?
(I tried to re-upload the image)
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Wednesday, October 31st, 2018 AT 6:15 AM
Tiny
JACOBANDNICKOLAS
  • EXPERT
Welcome back.

I have to be honest, I have never seen one repaired successfully. There is a rubber gasket in there, too. Once the crimps come loose and it starts leaking, they are difficult to fix. I would replace it.

However, if you want to try repairing it, I found directions for the process. You will need to purchase a rebuild kit (not sure if a dealer would have it) and special tools. Here are the directions. All attached pictures correlate with these directions.

__________________________________________________

REMOVAL AND INSTALLATION

REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE ENGINE UNDER COVERS
3. REMOVE RADIATOR ASSEMBLY
a. Disconnect the No.1 electric cooling fan connector.
B. Disconnect the No.2 electric cooling fan connector.
C. Disconnect the upper radiator hose.
D. Disconnect the lower radiator hose.
E. Disconnect the radiator reservoir hose.
F. Disconnect the A/T: 2 oil cooler hoses.
G. Remove the 2 bolts and upper radiator supports.
H. Remove the radiator assembly.
I. Remove the 2 lower radiator supports.
4. REMOVE ELECTRIC COOLING FAN FROM RADIATOR
Remove the 5 bolts and cooling fan assembly.

DISASSEMBLY
1. REMOVE DRAIN PLUG
a. Remove the drain plug.
B. Remove the O-ring.

2. DENSO Made: ASSEMBLE SPECIAL SERVICE TOOL (SST)
(SST) 09230-01010
a. Install the claw to the overhaul handle, inserting it in the hole in part "A" as shown in the diagram.
B. While gripping the handle, adjust the stopper bolts so that dimension "B" shown in the diagram is 0.2 - 0.3 mm (0.008 - 0.012 inch).

NOTICE: If this adjustment is not done the claw may be damaged.
3. DENSO Made: UNCAULK LOCK PLATES
Using SST to release the caulking, squeeze the handle until stopped by the stopper bolts.
SST 09230-01010
4. DENSO Made: REMOVE TANKS AND D-RINGS
Lightly tap the bracket of the radiator (or radiator inlet or outlet) with a soft-faced hammer, and remove the tank and the O-ring.
5. A/T (DENSO Made): REMOVE OIL COOLER FROM LOWER TANK
a. Remove the 2 nuts and 2 plate washers.
B. Remove the oil cooler and 2 O-rings.

INSPECTION
DENSO Made: INSPECT 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.

NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.

REASSEMBLY
1. A/T (DENSO Made): INSTALL OIL COOLER TO LOWER TANK
a. Install 2 new O-rings to the oil cooler.
B. Install the oil cooler to the lower tank.
C. Install the 2 plate washers and 2 nuts.
Torque: 8.34 Nm (85 kgf-cm, 74 inch lbs.)
2. DENSO Made: INSTALL NEW O-RINGS AND TANKS
a. After checking that there are no foreign objects in the lock plate groove, install the 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 prate with a soft-faced hammer so that there is no gap between it and the tank.
3. DENSO Made: ASSEMBLE SPECIAL SERVICE TOOL (SST)
(SST) 09230-01010, 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: 8.4 mm (0.331 inch)
4. DENSO Made: CAULK LOCK PLATE
a. Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, stopped by the stopped plate.
SST 09230-01010

HINT:
Do not stake the areas protruding around the pipes, brackets or tank rids.

The points shown in the illustration cannot be staked with SST. Use wrap vinyl tape around the tip of a pair or similar object and be careful not to damage the core plates.
B. Check the lock plate height (H) after completing the caulking.
Plate height: 7.40 - 7.80 mm (0.2913 - 0.3071 inch)
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.
6. INSPECT FOR WATER LEAKS
a. Tighten the drain plug.

B. Plug the inlet and outlet pipes of the radiator with SST.
SST 09230-01010
c. Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi)
d. Submerge the radiator in water.
E. 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 bubbles disappear.

INSTALLATION
1. INSTALL ELECTRIC COOLING FAN TO RADIATOR
Install the cooling fan with the 5 bolts.
Torque: 6 Nm (60 kgf-cm, 53 inch lbs.)

2. INSTALL RADIATOR ASSEMBLY
a. Install the 2 lower radiator supports to the radiator.
B. Attach the 2 lower radiator supports on the radiator to the body brackets.
C. Install the 2 upper radiator supports with the 2 bolts.
Torque: 13 Nm (130 kgf-cm, 9 ft. Lbs.)

HINT: After installation, check that the rubber cushion (A) of the support is not depressed.

D. W/ A/C: Install the A/C condenser with the 4 bolts.
E. Connect the upper radiator hose.
F. Connect the lower radiator hose.
G. Connect the radiator reservoir hose.
H. Connect the A/T: 2 oil cooler hoses to oil cooler pipes.
I. Connect the No.1 electric cooling fan connector.
J. Connect the No.2 electric cooling fan connector.
3. INSTALL ENGINE UNDER COVERS
4. FILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR COOLANT LEAKS
_____________________________________________

If you decide to try the repair. Let me know how it works out for you. However, by the time you get the rebuild kit (if available) and the tools, you most likely could have gotten a new radiator. Keep in mind, it could still leak after the repair.

Let me know what you decide and how thing turn out for you. If you have other questions or need help, let me know.

Take care,
Joe
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Wednesday, October 31st, 2018 AT 7:19 PM

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