Toyota Avalon (XX50): Oil Cooler

Components

COMPONENTS

ILLUSTRATION

*A	Type A	*B	Type B
*1	FRONT WHEEL OPENING EXTENSION PAD RH	*2	FRONT WHEEL OPENING EXTENSION PAD LH
*3	NO. 1 ENGINE UNDER COVER	*4	NO. 2 ENGINE UNDER COVER ASSEMBLY
*5	FRONT FENDER APRON SEAL LH	-	-
	N*m (kgf*cm, ft.*lbf): Specified torque	-	-

ILLUSTRATION

*1	NO. 1 INVERTER COOLING HOSE	*2	NO. 5 INVERTER COOLING HOSE
*3	MOTOR COOLING COOLER	*4	OIL COOLER UNION BOLT
*5	GASKET	*6	NO. 1 OIL COOLER TUBE CLAMP
*7	NO. 1 MOTOR COOLING HOSE	*8	NO. 2 MOTOR COOLING PIPE
*9	NO. 2 MOTOR COOLING HOSE	-	-
	N*m (kgf*cm, ft.*lbf): Specified torque	●	Non-reusable part

Installation

INSTALLATION

PROCEDURE

1. INSTALL NO. 1 MOTOR COOLING HOSE

HINT:

Perform this procedure only when replacement of the motor cooling cooler is necessary.

(a) Coat the pipe of the motor cooling cooler with a small amount of ATF as shown in the illustration.

ATF Application Area

(b) Install the No. 1 motor cooling hose to the motor cooling cooler, and slide the clip to secure it.

*a	0 to 3 mm (0 to 0.118 in.)
*b	2 to 7 mm (0.0787 to 0.276 in.)
*c	Paint Mark
*d	Center of Paint Mark
*e	120°
	Claw of Clip Location

NOTICE:

• Be careful not to deform the motor cooling cooler.
• Make sure to align the paint mark of the No. 1 motor cooling hose with the paint mark of the motor cooling cooler.
• Make sure that the claws of the clip are positioned within the area shown in the illustration.

2. INSTALL NO. 2 MOTOR COOLING HOSE

HINT:

Perform this procedure only when replacement of the motor cooling cooler is necessary.

(a) Coat the pipe of the motor cooling cooler with a small amount of ATF as shown in the illustration.

ATF Application Area

(b) Install the No. 2 motor cooling hose to the motor cooling cooler, and slide the clip to secure it.

*a	0 to 3 mm (0 to 0.118 in.)
*b	2 to 7 mm (0.0787 to 0.276 in.)
*c	Paint Mark
*d	Center of Paint Mark
*e	120°
	Claw of Clip Location

NOTICE:

• Be careful not to deform the motor cooling cooler.
• Make sure to align the paint mark of the No. 2 motor cooling hose with the paint mark of the motor cooling cooler.
• Make sure that the claws of the clip are positioned within the area shown in the illustration.

3. INSTALL NO. 2 MOTOR COOLING PIPE

(a) Install the No. 2 motor cooling pipe to the No. 2 motor cooling hose, and slide the clip to secure it.

*a	0 to 3 mm (0 to 0.118 in.)
*b	2 to 7 mm (0.0787 to 0.276 in.)
*c	Paint Mark
*d	Center of Paint Mark
*e	15°
	Center of Clip Location

NOTICE:

• Make sure to align the paint mark of the No. 2 motor cooling pipe with the paint mark of the No. 2 motor cooling hose.
• Make sure that the center of the clip (between the claws of the clip) is within 15° of the center of the paint mark as shown in the illustration.

4. INSTALL MOTOR COOLING COOLER

(a) Connect the No. 1 motor cooling hose to the transaxle housing tube connector, and slide the clip to secure it.

*a	0 to 3 mm (0 to 0.118 in.)
*b	2 to 7 mm (0.0787 to 0.276 in.)
*c	Paint Mark
*d	Rib
*e	Center of Rib
*f	180°
	Claw of Clip Location

NOTICE:

• Make sure to align the paint mark of the No. 1 motor cooling hose with the rib of the hybrid vehicle transaxle assembly.
• Make sure that the claws of the clip are within the location shown in the illustration.

(b) Temporarily install the motor cooling cooler to the No. 1 transmission control cable bracket with the 3 bolts.

(c) Tighten the 3 bolts in the order shown in the illustration.

Torque:

11.5 N·m {117 kgf·cm, 8 ft·lbf}

(d) Temporarily install the No. 2 motor cooling pipe to the hybrid vehicle transaxle assembly with the oil cooler union bolt and a new gasket.

*1 Oil Cooler Union Bolt *2 Gasket

(e) Install the No. 2 motor cooling pipe to the hose bracket with the bolt and No. 1 oil cooler tube clamp. Torque: 11.5 N·m {117 kgf·cm, 8 ft·lbf}

(f) Tighten the oil cooler union bolt. Torque: 35 N·m {357 kgf·cm, 26 ft·lbf}

5. CONNECT NO. 5 INVERTER COOLING HOSE

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6. INSTALL NO. 1 INVERTER COOLING HOSE

(a) Install the No. 1 inverter cooling hose to the motor cooling cooler, and slide the clip to secure it.

*a	2 to 7 mm (0.0787 to 0.276 in.)
*b	Paint Mark
*c	Center of Paint Mark
*d	120°
	Claw of Clip Location

NOTICE:

• Be careful not to deform the motor cooling cooler.
• Make sure to align the paint mark of the No. 1 inverter cooling hose with the paint mark of the motor cooling cooler.
• Make sure that the claws of the clip are positioned within the area shown in the illustration.

7. INSTALL INVERTER WITH CONVERTER ASSEMBLY

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8. INSPECT HYBRID TRANSAXLE FLUID

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9. INSPECT FOR HYBRID TRANSAXLE FLUID LEAK

10. INSTALL FRONT FENDER APRON SEAL LH

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11. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

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12. INSTALL NO. 1 ENGINE UNDER COVER

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13. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

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14. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

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Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during motor cooling cooler removal/installation are shown below.

CAUTION:

• Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

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• To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

NOTICE:

• After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

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• If the ECM has been struck or dropped, replace it.
• Perform Vehicle Identification Number (VIN) registration when replacing the ECM.

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PROCEDURE

1. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

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2. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

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3. REMOVE NO. 1 ENGINE UNDER COVER

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4. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY

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5. REMOVE FRONT FENDER APRON SEAL LH

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6. REMOVE INVERTER WITH CONVERTER ASSEMBLY

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7. REMOVE NO. 1 INVERTER COOLING HOSE

(a) Slide the clip and remove the No. 1 inverter cooling hose from the motor cooling cooler.

8. DISCONNECT NO. 5 INVERTER COOLING HOSE

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9. REMOVE MOTOR COOLING COOLER

(a) Remove the oil cooler union bolt and gasket to disconnect the No. 2 motor cooling pipe from the hybrid vehicle transaxle assembly.

*1 Oil Cooler Union Bolt *2 No. 1 Oil Cooler Tube Clamp

(b) Remove the bolt and No. 1 oil cooler tube clamp to disconnect the No. 2 motor cooling pipe from the hose bracket.

(c) Remove the 3 bolts to disconnect the motor cooling cooler from the No. 1 transmission control cable bracket.

(d) Slide the clip and disconnect the No. 1 motor cooling hose from the transaxle housing tube connector. NOTICE: Make sure not to remove the No. 1 motor cooling hose from the motor cooling cooler as the motor cooling cooler may be deformed.

10. REMOVE NO. 2 MOTOR COOLING PIPE

(a) Slide the clip and remove the No. 2 motor cooling pipe from the No. 2 motor cooling hose. NOTICE: Make sure not to remove the No. 2 motor cooling hose from the motor cooling cooler as the motor cooling cooler may be deformed.