TOYOTA AVALON 2001 Service Repair Manual

CO030-01
CO-22
- COOLINGRADIATOR
1215 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
Installation is in the reverse order of removal (See page CO-17).

CO09H-01
- COOLINGRADIATOR
CO-13
1206 Author
: Date
:
2001 AVALON (RM808U)
RADIATOR
ON-VEHICLE CLEANING
Using water or a steam cleaner, remove any mud or dirt from the radiator core.
NOTICE:
If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Main-
tain a distance between the cleaner nozzle and radiator core)

CO09I-02
Z00570
Radiator Cap Tester
30° or More
Radiator Cap
P13014
Radiator Cap
Tester CO-14
- COOLINGRADIATOR
1207 Author
: Date
:
2001 AVALON (RM808U)
ON-VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blow out under pressure.
2. INSPECT RADIATOR CAP
NOTICE:

If the radiator cap has contaminations, always rinse
it with water.

When performing steps (a) and (b) below, keep the ra-
diator cap tester at an angle of over 30° above the hor-
izontal.

Before using a radiator cap tester, wet the relief valve
and pressure valve with engine coolant or water.
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push/(3 seconds or more)
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the tester and measure the relief valve opening
pressure.
Pump speed: 1 push within 1 second
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum valve). After this, the pump speed can be re-
duced.
Standard opening pressure:
83 - 113 kPa (0.85 - 1.15 kgf/cm
2, 12.1 - 16.4 psi)
Minimum opening pressure:
69 kPa (0.7 kgf/cm
2, 10.0 psi)
HINT:
Use the tester's maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant, and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 127 kPa (1.3 kgf/cm
2, 18.5 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and cylinder head.
4. REINSTALL RADIATOR CAP

CO02Z-03
S04435
(1)(2)
(3)(4) (5) (6)
CO1267
Lock Plate
Lock Plate
Core
CO0317
O-Ring Normal
X Twisted
X Twisted
- COOLINGRADIATOR
CO-19
1212 Author
: Date
:
2001 AVALON (RM808U)
REASSEMBLY
1. INSTALL OIL COOLER TO LOWER TANK
(a) Clean the O-ring contact surface of the lower tank and oil
cooler.
(b) Install a new O-rings (1) to the oil cooler (2).
(c) Install the oil cooler with the O-rings to the lower tank (3).
(d) Install the plate washers (4), and nuts (5). Torque the
nuts.
Torque: 8.3 N´m (85 kgf´cm, 74 in.´lbf)
(e) Install the pipe (6).
Torque: 14.7 N´m (150 kgf´cm, 11 ft´lbf)
2. INSPECT LOCK PLATE
Inspect the lock plate for damage.
HINT:

If the sides of the lock plate groove are deformed, reas-
sembly of the tank will be impossible.

Therefore, first correct any deformation with pliers or simi-
lar object. Water leakage will result if the bottom of the
lock plate groove is damaged or dented, Therefore, repair
or replace if necessary.
NOTICE:
The radiator can only be recaulked 2 times. After the 2nd
time, the radiator core must be replaced.
3. 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 pa-
per without scratching it.

B09047
Ta pCORRECT
WRONGTank
Lock
Plate
CO1206
Dimension ºBº
Stopper Bolt
Punch Assembly
Overhaul HandlePart ºAº
SST
B09045
1
SST
Stopper
Bolt2 37
5
48
6
TankLock
Plate
B09044
Rib
Bracket
CO-20
- COOLINGRADIATOR
1213 Author
: Date
:
2001 AVALON (RM808U)
(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 it and the tank.
4. ASSEMBLE SST
SST 09230-01010, 09231-14010
(a) Install the punch assembly to the overhaul handle, insert-
ing it in the hole in part ºAº as shown in the illustration.
(b) While gripping the handle, adjust the stopper bolt so that
dimension ºBº shown in the diagram.
Dimension ºBº: 8.4 mm (0.34 in.)
5. 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 squeezing the handle until
stopped by the stopper plate.
SST 09230-01010
HINT:

Do not stake the areas protruding around the pipes,
brackets or tank ribs.

B09041
B09046
H
- COOLINGRADIATOR
CO-21
1214 Author
: Date
:
2001 AVALON (RM808U)

The points shown in the rib sides and oil cooler near here
cannot be staked with SST. Use pliers or similar object
and be careful not to damage the core plates.
(b) Check the lock plate height (H) after completing the caulk-
ing.
Plate height (H): 7.4 - 7.8 mm (0.2959 - 0.3119 in.)
If not within the specified height, adjust the stopper bolt of the
handle again and caulk again.
6. INSTALL CUSHION

CO0WT-01
B09040
- COOLINGRADIATOR
CO-17
1210 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
HINT:
At the time of installation, please refer to the following items.

Start the engine, and check for coolant and A/T fluid
leaks.

Check the A/T fluid level (See page DI-160).
1. REMOVE BATTERY AND BATTERY TRAY
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT
4. DISCONNECT NO.3 ENGINE ROOM RELAY BLOCK
FROM RADIATOR
5. DISCONNECT NO.1 COOLING FAN CONNECTOR
6. DISCONNECT WIRE CLAMPS FROM NO.1 FAN
SHROUD
7. DISCONNECT NO.2 COOLING FAN CONNECTOR
8. DISCONNECT NO.1 ECT SWITCH WIRE CONNECTOR
9. DISCONNECT WIRE CLAMPS FROM NO.2 FAN
SHROUD
10. DISCONNECT UPPER RADIATOR HOSE FROM RA-
DIATOR
11. DISCONNECT LOWER RADIATOR HOSE FROM RA-
DIATOR
12. DISCONNECT A/T OIL COOLER HOSES FROM RA-
DIATOR
13. REMOVE RADIATOR AND COOLING FANS AS-
SEMBLY
(a) Remove the 2 bolts and 2 upper supports.
Torque: 12.8 N´m (130 kgf´cm, 9 ft´lbf)
(b) Lift out the radiator, and remove the radiator and cooling
fans assembly.
(c) Remove the 2 lower supports.
14. REMOVE NO.1 ECT SWITCH
15. REMOVE NO.1 COOLING FAN FROM RADIATOR
Remove the 2 bolts and cooling fan.
Torque: 5.0 N´m (50 kgf´cm, 44 in.´lbf)
16. REMOVE NO.2 COOLING FAN FROM RADIATOR
Remove the 2 bolts and cooling fan.
Torque: 5.0 N´m (50 kgf´cm, 44 in.´lbf)

CO02Q-03
B09035
V-Bank Cover
Air Cleaner Hose
w/ Resonator
Engine Wire Protector
Thermostat

Gasket
Water Inlet
Water Inlet PipeN´m (kgf´cm, ft´lbf)
: Specified torque

O-Ring
No.2 ECT
Switch
Connector
8 (80, 69 in.´lbf)
19.5 (200, 14)

Non-reusable part
Vacuum Hose
Heater Hose
V-Bank Cover Fastener
- COOLINGTHERMOSTAT
CO-9
1202 Author
: Date
:
2001 AVALON (RM808U)
THERMOSTAT
COMPONENTS

CO02S-03
P13255
CO0601
Z1057910 mm
- COOLINGTHERMOSTAT
CO-1 1
1204 Author
: Date
:
2001 AVALON (RM808U)
INSPECTION
INSPECT THERMOSTAT
HINT:
The thermostat is numbered with the valve opening tempera-
ture.
(a) Immerse the thermostat in water and gradually heat the
water.
(b) Check the valve opening temperature.
Valve opening temperature:
80 - 84°C (176 - 183°F)
If the valve opening temperature is not as specified, replace the
thermostat.
(c) Check the valve lift.
Valve lift: 10.0 mm (0.394 in.) or more at 95°C (203°F)
If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve is fully closed when the thermostat
is at low temperatures (below 40°C (104°F)).
If not closed, replace the thermostat.

CO02T-03
B04153Stud BoltJiggle Valve
15°15°
CO-12
- COOLINGTHERMOSTAT
1205 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
1. PLACE THERMOSTAT IN WATER PUMP
(a) Install a new gasket on to the thermostat.
(b) Align the thermostat jiggle valve with the upper stud bolt,
and insert the thermostat in the water inlet housing.
HINT:
The jiggle valve may be set within 15° of either side of the pre-
scribed position.
2. INSTALL WATER INLET
Install the water inlet with the 3 nuts.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
3. INSTALL WATER INLET PIPE
(a) Install a new O-ring to the water inlet pipe.
(b) Apply soapy water to the O-ring.
(c) Connect the water inlet pipe to the water inlet.
(d) Install the bolt holding the water inlet pipe to the LH cylin-
der head.
Torque: 19.5 N´m (200 kgf´cm, 14 ft´lbf)
4. INSTALL ENGINE WIRE PROTECTOR
5. CONNECT NO.2 ECT SWITCH CONNECTOR
6. CONNECT HEATER HOSES
7. REINSTALL AIR CLEANER HOSE WITH RESONATOR
8. INSTALL V-BANK COVER
(a) Using 5 mm hexagon wrench, install the V-bank cover
with the 3 cap nuts.
(b) Press down the V-bank cover fastener.
9. FILL WITH ENGINE COOLANT
10. START ENGINE AND CHECK FOR LEAKS
11. RECHECK ENGINE COOLANT LEVEL