TOYOTA SIENNA 2007 Service Repair Manual

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(c) Using SST, uncrimp the lock plate by squeezing the
handle until stopped by the stopper bolt.
SST 09230-01010
(d) Lightly tap the bracket of the radiator (or radiator
hose inlet or outlet) with a soft-faced hammer and
remove the tank.
(e) Remove the O-ring.
4. REMOVE UPPER RADIATOR TANK
HINT:
The removal procedure for the upper radiator tank is the
same as that for the lower radiator tank.
INSPECTION
1. INSPECT LOCK PLATE FOR DAMAGE
(a) Inspect the lock plate for damage.
HINT:
• Reassembly of a deformed tank will be
impossible. Therefore, first correct the shape of
the lock plate groove with pliers or a similar tool,
if necessary.
• Water leakage will result if the bottom of the lock
plate groove is damaged or dented. Repair or
replace the locking plate if necessary.
NOTICE:
The radiator can only be crimped 3 times. After
recrimping 2 times, the radiator core must be
replaced.
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REASSEMBLY
1. INSTALL LOWER RADIATOR TANK
(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 sandpaper without scratching it.
(b) Tap the lock plate with a plastic-faced hammer so
that there is no gap between the lock plate and the
tank.
NOTICE:
Do not tap the areas protruding around the
pipes, brackets or tank ribs.
(c) Install the punch assembly to the overhaul handle,
inserting it in the hole in part A as shown in the
illustration.
SST 09230-01010 (09231-01010, 09231-01020),
09231-14010
(d) While gripping the handle, adjust the stopper bolt so
that dimension B is as specified below.
Dimension B:
8.8 mm (0.347 in.)
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(e) Lightly press SST against the lock plate in the order
shown in the illustration. After repeating this
procedure a few times, fully crimp the lock plate by
squeezing the handle until stopped by the stopper
bolt.
SST 09230-01010 (09231-01010, 09231-01020),
09231-14010
NOTICE:
• Do not crimp the protruding areas around
ports A and brackets B.
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• Do not use SST to crimp the circled areas
indicated in the illustration. Use pliers and be
careful not to damage the core plates.
(f) Check the lock plate height A after completing the
crimping.
Standard plate height A:
8.8 mm (0.347 in.)
If the height is not as specified, readjust the stopper
bolt of the handle and crimp the lock plate again.
2. INSTALL UPPER RADIATOR TANK
HINT:
The installation procedure for the upper radiator tank is
the same as that for the lower radiator tank.
3. INSTALL DRAIN PLUG
(a) Install a new O-ring to the drain plug.
(b) Install a new O-ring to the air drain plug.
(c) Install the drain plug and air drain plug.
4. INSPECT FOR WATER LEAK
(a) Plug the inlet and outlet pipes of the radiator with
SST.
SST 09230-01010 (09231-00030, 09231-00060)
(b) Using a radiator cap tester, apply pressure to the
radiator.
Standard test pressure:
177 kPa (1.8 kgf/cm
2, 26 psi)
(c) Submerge the radiator in water.
(d) Inspect for leak.
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.
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5. INSTALL RADIATOR WATER INLET
(a) Install the radiator water inlet with the 2 bolts.
Torque: 7.1 N*m (72 kgf*cm, 63 in.*lbf)
INSTALLATION
1. CONNECT INLET SUB-ASSEMBLY
(a) Connect the inlet hose to the radiator.
(b) Install the inlet sub-assembly to the radiator with the
bolt.
Torque: 7.1 N*m (72 kgf*cm, 63 in.*lbf)
2. INSTALL NO. 2 RADIATOR SUPPORT
(a) Install the No. 2 radiator support to the radiator with
the 2 bolts.
Torque: 12.7 N*m (130 kgf*cm, 112 in.*lbf)
3. INSTALL RADIATOR SUPPORT LOWER
(a) Install the 2 radiator support lowers to the radiator.
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4. INSTALL FAN SHROUD WITH FAN MOTOR
(a) Install the fan shroud with fan motor to the radiator
with the 2 bolts.
Torque: 6 N*m (61 kgf*cm, 4 ft.*lbf)
5. INSTALL RADIATOR ASSEMBLY WITH FAN SHROUD
AND FAN MOTOR
(a) Install the radiator assembly with fan shroud and fan
motor.
(b) Install the condenser assembly to the radiator
assembly with fan shroud and fan motor with the 2
bolts.
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
6. INSTALL NO. 1 RADIATOR SUPPORT
(a) Install the No. 1 radiator support to the radiator
assembly with the 6 bolts.
Torque: Bolt A
13 N*m (130 kgf*cm, 9 ft.*lbf)
Bolt B
3.9 N*m (40 kgf*cm, 35 in.*lbf)
Bolt C
6 N*m (61 kgf*cm, 4 ft.*lbf)
(b) Attach the clamp.
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7. INSTALL RADIATOR SUPPORT CUSHION
(a) Install the 2 radiator support cushions to the No. 1
radiator support.
8. INSTALL PRESSURE FEED TUBE ASSEMBLY
(a) Install the 2 bolts.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
9. INSTALL HEADLIGHT BRACKET RH
(a) Install the headlight bracket RH with the 3 nuts.
10. INSTALL RADIATOR SIDE DEFLECTOR RH
(a) Engage the 3 claws to install the radiator side
deflector RH.
11. INSTALL HEADLIGHT ASSEMBLY RH
(a) The installation procedure of the RH side is the
same as the LH side.
HINT:
See page LI-78
12. CONNECT NO. 2 OIL COOLER OUTLET TUBE SUB-
ASSEMBLY
(a) Install the No. 2 oil cooler outlet tube sub-assembly
with the 2 bolts.
Torque: 6 N*m (61 kgf*cm, 4 ft.*lbf)
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(b) Connect the No. 1 transmission oil cooler hoses to
the radiator.
(c) Connect the No. 1 oil cooler inlet and No. 1 oil
cooler outlet hoses to the No. 2 oil cooler outlet tube
sub-assembly.
13. INSTALL RADIATOR UPPER SUPPORT SUB-
ASSEMBLY
(a) Install the radiator upper support sub-assembly with
the 4 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
14. CONNECT COOLING FAN ECU CONNECTOR
(a) Connect the connector.
(b) Attach the clamp.
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15. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY
(a) Install the hood lock support sub-assembly with the
2 bolts.
(b) Attach the clamp.
(c) Connect the low pitched horn and high pitched horn
connectors.
(d) Connect the ambient temperature sensor connector.
16. INSTALL HOOD LOCK ASSEMBLY
(a) Connect the cable to the hood lock assembly.
(b) Install the hood lock assembly with the 3 bolts.
Torque: 8 N*m (82 kgf*cm, 6 ft.*lbf)
(c) With Hood Courtesy Switch:
(1) Connect the connector.
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17. INSTALL HOOD LOCK RELEASE LEVER
PROTECTOR
(a) Engage the 4 claws to install the hood lock release
lever protector.
18. CONNECT NO. 2 RADIATOR HOSE
(a) Connect the No. 2 radiator hose to the radiator.
19. CONNECT NO. 1 RADIATOR HOSE
(a) Connect the No. 1 radiator hose to the radiator.
20. CONNECT RADIATOR RESERVE TANK HOSE OR
PIPE
(a) Connect the radiator reserve tank hose or pipe to
the radiator.
21. INSTALL NO. 1 AIR CLEANER INLET (See page EM-
59)
22. INSTALL FRONT BUMPER ENERGY ABSORBER
23. INSTALL FRONT BUMPER ASSEMBLY (See page ET-
9)
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