2001 TOYOTA AVALON Service Repair Manual

CO-30
- COOLINGENGINE COOLANT TEMPERATURE (ECT) SWITCH
1223 Author
: Date
:
2001 AVALON (RM808U)
4. REFILL ENGINE COOLANT
5. START ENGINE AND CHECK FOR COOLANT LEAKS

CO02W-03
B09039
Radiator
No.1 ECT Switch
No.2 Cooling Fan Connector
Upper Radiator
Support
Upper Radiator
HoseNo.1 Cooling Fan Connector
No.1 ECT Switch Wire Connector
Radiator Assembly
Lower Radiator
Support
O-Ring
A/T Oil Cooler Hose
No.3 Engine
Room Relay Block No.1 Cooling Fan

Non-reusable part
O-Ring
Drain Plug
Lower Radiator
Hose
No.2 Cooling Fan
Battery
Insulator
Battery
Battery
Tray Hold-Down
Clamp
Engine Under Cover
- COOLINGRADIATOR
CO-15
1208 Author
: Date
:
2001 AVALON (RM808U)
COMPONENTS

B09036

O-Ring

Non-reusable partUpper Tank
Cushion
Core
Oil Cooler
Lower TankInlet Pipe
Plate WasherNut

O-Ring
O-Ring
CO-16
- COOLINGRADIATOR
1209 Author
: Date
:
2001 AVALON (RM808U)

CO02Y-03
CO1205
Dimension ºBºPart ºAº
Stopper Bolt SST
Claw
Overhaul Handle
B09048
Tank
SST
Lock Plate
Stopper Bolt
B09042
Ta p
B09043
CO-18
- COOLINGRADIATOR
1211 Author
: Date
:
2001 AVALON (RM808U)
DISASSEMBLY
1. REMOVE CUSHION FROM RADIATOR
2. ASSEMBLE SST
SST 09230-01010
(a) Install the claw to the overhaul handle, inserting it in the
hole in part ºAº as shown in the diagram.
(b) While gripping the handle, adjust the stopper bolt so that
dimension ºBº shown in the diagram is 0.2 - 0.5 mm
(0.008 - 0.020 in.).
NOTICE:
If this adjustment is not done, the claw may be damaged.
3. UNCAULK LOCK PLATES
Using SST to release the caulking, squeeze the handle until
stopped by the stopper bolt.
SST 09230-01010
4. REMOVE TANKS AND O-RINGS
(a) Lightly tap the bracket of the radiator (or radiator hose in-
let or outlet) with a soft-faced hammer and remove the
tank.
(b) Remove the O-ring.
5. REMOVE OIL COOLER FROM LOWER TANK
(a) Remove the pipe.
(b) Remove the nuts and plate washers.
(c) Remove the oil cooler and O-rings.

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.