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Engine Cooling System: Removal & Installation Toyota Avalon XX30

Cooling System (Mechanical) 44 illustrations ~1521 words

REMOVAL

  1. DRAIN ENGINE COOLANT
  2. REMOVE V-BANK COVER SUB-ASSEMBLY
  3. REMOVE ENGINE MOVING CONTROL ROD
  4. REMOVE ENGINE MOUNTING CONTROL BRACKET
  5. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH
  6. REMOVE FAN AND GENERATOR V BELT
  7. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.2
  8. SEPARATE RADIATOR HOSE OUTLET
  9. REMOVE WATER INLET Remove the 2 bolts and water inlet.
  10. REMOVE THERMOSTAT

Scheme 35

Scheme 35: INSPECTION
Scheme 35: INSPECTION

Scheme 36

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Scheme 36

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Scheme 37
Scheme 37
  1. INSPECT THERMOSTAT Inspect the thermostat. HINT: The thermostat is numbered with the valve opening temperature. Immerse the thermostat in water and gradually heat the water. Check the valve opening temperature. Valve opening temperature: 80 to 84°C (176 to 183°F) If the valve opening temperature is not as specified, replace the thermostat. Check the valve lift. Valve lift: 7.7 mm (0.3031 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. Check that the valve is fully closed when the thermostat is at low temperature (below 40°C (104°F)). If not closed, replace the thermostat.

Scheme 38

Scheme 38: INSTALLATION
Scheme 38: INSTALLATION
  1. INSTALL THERMOSTAT Install a new gasket to the thermostat. Install the thermostat with the jiggle valve facing up. HINT: The jiggle valve may be set within 10°of either side of the prescribed position.
  2. INSTALL WATER INLET Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  3. INSTALL RADIATOR HOSE OUTLET
  4. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.2
  5. INSTALL FAN AND GENERATOR V BELT
  6. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH
  7. INSTALL ENGINE MOUNTING CONTROL BRACKET
  8. INSTALL ENGINE MOVING CONTROL ROD
  9. INSTALL V-BANK COVER SUB-ASSEMBLY
  10. ADD ENGINE COOLANT
  11. CHECK FOR ENGINE COOLANT LEAKS

Scheme 39

Scheme 39: COMPONENTS
Scheme 39: COMPONENTS

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Scheme 41

Scheme 41: ON-VEHICLE CLEANING
Scheme 41: ON-VEHICLE CLEANING
  1. INSPECT FINS BLOCKAGE If the fins are clogged, wash them with water or a steam cleaner. Dry with compressed air. NOTE: If the distance between the steam cleaner and the core is too close, the fins may become damaged. Keep the following injection distance. Standard INJECTION DISTANCE Injection Distance Injection Pressures 300 mm (11.81 in.) 2,942 to 4,903 kPa (30 to 50 kg/cm 2 , 427 to 711 psi) 500 mm (19.69 in.) 4,903 to 7,845 kPa (50 to 80 kg/cm 2 , 711 to 1,138 psi) If the fins are bent, straighten them with a screwdriver or pliers. Never apply water directly onto the electronic components.

Scheme 42

Scheme 42: REMOVAL
Scheme 42: REMOVAL

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Scheme 53
  1. DRAIN ENGINE COOLANT
  2. REMOVE BATTERY
  3. REMOVE AIR CLEANER INLET NO.2
  4. REMOVE AIR CLEANER INLET NO.1
  5. SEPARATE RADIATOR RESERVE TANK HOSE OR PIPE Separate radiator reserve tank hose from the radiator assembly.
  6. SEPARATE RADIATOR HOSE INLET Separate radiator hose inlet from the radiator assembly.
  7. SEPARATE RADIATOR HOSE OUTLET Separate radiator hose outlet from the radiator assembly.
  8. SEPARATE OIL COOLER INLET TUBE NO.1 Separate oil cooler inlet tube No.1 from the radiator assembly.
  9. SEPARATE OIL COOLER OUTLET TUBE NO.1 Separate oil cooler outlet tube No.1 from the radiator assembly.
  10. REMOVE RADIATOR SUPPORT UPPER Remove the hood lock nut cap from the hood lock assembly. Remove the 3 bolts and separate the hood lock assembly from the radiator support upper. Remove the 5 bolts and radiator support upper.
  11. REMOVE RADIATOR ASSEMBLY Disconnect the fan motor connector. Remove the 4 bolts and separate the condenser assembly from the radiator assembly. Remove the radiator assembly from the body.
  12. REMOVE RADIATOR SUPPORT CUSHION Remove the 2 radiator support cushions from the radiator assembly.
  13. REMOVE RADIATOR SUPPORT LOWER Remove the 2 radiator support lowers from the radiator assembly.
  14. REMOVE FAN ASSEMBLY WITH MOTOR Disassemble the 3 snap fits and lift the fan assembly w/motor from the radiator.

Scheme 54

Scheme 54: DISASSEMBLY
Scheme 54: DISASSEMBLY

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Scheme 57
  1. REMOVE DRAIN PLUG Remove the drain plug. Remove the O-ring.
  2. ASSEMBLE SST SST 09230-01010 (09231-01010, 09231-01030) Install the claw to the overhaul handle, inserting it in the hole in part A (Scheme 54) While gripping the handle, adjust the stopper bolt so that dimension B is (Scheme 54) Dimension B: 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.
  3. 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)
  4. REMOVE RADIATOR TANK UPPER AND TANK LOWER Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft-faced hammer and remove the tank. Remove the O-ring.
  5. REMOVE OIL COOLER ASSEMBLY Remove the screw and cooler pipe. Remove the nut and plate washer. Remove the oil cooler. Remove the 2 O-rings from the oil cooler.

Scheme 58

Scheme 58: INSPECTION
Scheme 58: INSPECTION
  1. INSPECT LOCK PLATE 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 the lock plate groove's shape with pliers or a similar object, if necessary. Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace if necessary. NOTE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.

Scheme 59

Scheme 59: REASSEMBLY
Scheme 59: REASSEMBLY

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Scheme 66
  1. INSTALL OIL COOLER ASSEMBLY Clean the O-rings contact surface of the lower tank and oil cooler. Install 2 new O-rings to the oil cooler. Install the oil cooler to the lower tank. Install the plate washer and nut. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) Install the cooler pipe. Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf) Install the screw.
  2. INSTALL RADIATOR TANK UPPER AND TANK LOWER 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. Install the tank without damaging the O-ring. Tap the lock plate with a soft-faced hammer so that there is no gap between the lock plate and the tank.
  3. ASSEMBLE SST SST 09230-01010, 09231-14010 Install the punch assembly to the overhaul handle, inserting it in the hole in part A (Scheme 62) While gripping the handle, adjust the stopper bolt so that dimension B is (Scheme 62) Dimension B: 8.4 mm (0.331 in.)
  4. CAULK LOCK PLATE Lightly press SST against the lock plate in the order (Scheme 63) After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate. SST 09230-01010 HINT: Do not tap the areas protruding around the pipes, brackets or tank ribs. The dotted circles shown in the illustration and parts of the oil cooler near the dotted circles cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates. 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 and caulk again.
  5. INSTALL DRAIN PLUG Install a new O-ring to the drain plug. Install the drain plug.
  6. INSPECT FOR WATER LEAKS Plug the inlet and outlet pipes of the radiator with SST. SST 09230-01010 Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm 2, 26 psi) Submerge the radiator in water. Inspect for leaks. HINT: On radiators with resin tanks, there is 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.

Scheme 67

Scheme 67: INSTALLATION
Scheme 67: INSTALLATION

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Scheme 78
  1. INSTALL FAN MOTOR WITH MOTOR Install the fan assembly w/ motor to the radiator with the 2 guides at the bottom and 3 snap fits on the top.
  2. INSTALL RADIATOR SUPPORT LOWER Install the 2 radiator support lowers to the radiator assembly.
  3. INSTALL RADIATOR SUPPORT CUSHION Install the 2 radiator support cushions to the radiator assembly.
  4. INSTALL RADIATOR ASSEMBLY Install the radiator to the body. Install the condenser assembly with the 4 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Connect the fun motor connector.
  5. INSTALL RADIATOR SUPPORT UPPER Install the radiator support upper with the 5 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) Install the hood lock assembly to the radiator support upper with the 3 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Install the hood lock nut cap to the hood lock assembly.
  6. INSTALL OIL COOLER OUTLET TUBE NO.1 Install oil cooler outlet tube No.1 to the radiator assembly.
  7. INSTALL OIL COOLER INLET TUBE NO.1 Install oil cooler inlet tube No.1 to the radiator assembly.
  8. INSTALL RADIATOR HOSE OUTLET Install radiator hose outlet to the radiator assembly.
  9. INSTALL RADIATOR HOSE INLET Install radiator hose inlet to the radiator assembly.
  10. INSTALL RADIATOR RESERVE TANK HOSE OR PIPE Install radiator reserve tank hose to the radiator assembly.
  11. INSTALL AIR CLEANER INLET NO.1
  12. INSTALL AIR CLEANER INLET NO.2
  13. INSTALL BATTERY
  14. ADD ENGINE COOLANT
  15. CHECK FOR ENGINE COOLANT LEAKS

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