OEM 2004 Toyota Avalon Radiator

2004 Toyota Avalon Parts Questions & Experts Answers

• Q: How to service and repair the radiator on 2004 Toyota Avalon?

  A: Beginning the radiator service and repair requires first removing the cushion installed on the unit. Special Service Tool 09230-01010 consists of a claw which needs attachment to the overhaul handle before use. Insert the tool in part "A" while setting the stopper bolt at dimension "B" between 0.2 - 0.5 mm (0.008 - 0.020 inch) to protect the claw from damage. Use the same tool to uncaulk the lock plates through handle compression that stops when reaching the stopper bolt. When removing the tanks and O-rings you can use a soft-faced hammer to tap the radiator bracket gently then detach the O-ring. The next step involves removing the oil cooler by unfastening the pipe, nuts along with plate washers and then extracting both the cooler and O-rings. During reassembly you should first prepare the O-ring contact surfaces of both components. You must install new O-rings (1) to the oil cooler (2) then unite the oil cooler with new O-rings to the lower tank (3). The installation requires plate washers (4) and nuts (5) to be secured before torquing the nuts to 8.3 Nm (85 kgf-cm, 74 inch lbs.) and the pipe (6) to 14.7 Nm (150 kgf-cm, 11 ft. lbs.). Drug the lock plate for damage because any deformation requires plier correction to stop water leakage and reassembly problems. The radiator core replacement becomes necessary after the second successful recaulking process. New O-rings and tanks must be installed while checking for any foreign materials inside the lock plate groove before gently tapping this section with a soft-faced hammer to minimize gaps. Preparation of Special Service Tools 09230-01010 and 09231-14010 requires installation of the punch setup on the overhaul handle while users adjust the stopper bolt to reach dimension "B": 8.4 mm (0.34 inch). Caulk the lock plate through mild tool compression that uses handle pressure until the stopper plate stops advancement while keeping away from staking on pipes brackets and tank ribs. The lock plate height (H) must be verified between 7.4 and 7.8 mm while adjusting for proper height before installing the cushion.