OEM 2006 Toyota Avalon Radiator

2006 Toyota Avalon Parts Questions & Experts Answers

• Q: How to overhaul the radiator assembly on 2006 Toyota Avalon?

  A: The first step for radiator assembly (2GR-FE) overhaul requires removal of the drain plug along with its O-ring. Special Service Tool: 09230-01010 (09231-01010, 09231-01030) requires the claw installation onto the overhaul handle and stopper bolt adjustment for proper dimension B measurement between 0.2 to 0.3 mm (0.008 to 0.012 inch) to safeguard components. Apply the tool to break the caulking on the lock plate before removing the upper and lower radiator tanks by tapping gently with a soft-faced hammer while taking out the O-ring. Proceed by uninstalling these components starting with the screw releasing the cooler pipe then the nut and plate washer followed by removal of the oil cooler while you remove both O-rings. Install the lower radiator tank with the oil cooler by using a plate washer and nut according to a torque of 8.3 Nm (85 kgf-cm, 73 inch lbs.) after installing new O-rings on the oil cooler's surfaces. Finally secure the cooler pipe with 15 Nm (150 kgf-cm, 11 ft. lbs.) torque and then tighten the screw. Examine the lock plate for signs of damage while checking for any deformations or dents in the groove because water can leak through these defects; perform repairs or replacement if needed but remember that radiator core replacements must occur twice until a full replacement is necessary. Install the upper and lower radiator tanks while checking that no debris exists in the lock plate groove and deploying a fresh O-ring without rotation. Use a soft-faced hammer to strike the lock plate while eliminating all gaps. Special Service Tools 09230-01010 and 09231-14010 must be assembled while adjusting the stopper bolt to reach B dimension at 8.4 mm (0.331 inch). Start locking the plate with the tool after pressing it to block the plates then stop pressing the handle when it reaches the stopper plate position. Do not tap on the pipes or brackets. Check the lock plate height (H) between 7.40 to 7.80 mm (0.2913 to 0.3071 inch) after caulking and readjust it if needed. After installing a new O-ring onto the drain plug you should secure it by plugging the inlet and outlet pipes with Special Service Tool: 09230-01010, followed by application of 177 kPa (1.8 kgf/cm2, 26 psi) test pressure using a radiator cap tester and complete the inspection for leaks while aware that trapped air in resin tanks can create false leak indicators.