Toyota Avalon Service & Repair Manual: Installation

INSTALLATION

PROCEDURE

1. INSTALL LOWER RADIATOR SUPPORT

(a) Install the 2 lower radiator supports to the radiator assembly.

2. INSTALL RADIATOR SUPPORT CUSHION

(a) Install the 2 radiator support cushions to the radiator assembly.

3. INSTALL RADIATOR ASSEMBLY

(a) Engage the 2 guides.

(b) Engage the 2 claws to install the fan with motor assembly to the radiator assembly.

NOTICE:

Do not damage the radiator assembly when installing the fan with motor assembly.

(c) Install the radiator assembly with the fan with motor assembly to the vehicle body.

NOTICE:

Do not apply excessive force to the cooler condenser assembly or pipe when installing the radiator assembly with the fan with motor assembly.

(d) Engage the 2 guides.

(e) Engage the 2 claws to install the cooler condenser assembly to the radiator assembly.

NOTICE:

Make sure not to damage the cooler condenser assembly when installing the cooler condenser assembly.

(f) Engage the wire harness clamp.

(g) Connect the cooling fan motor connector and rotate the lever to lock it.

NOTICE:

  • When connecting the cooling fan motor connector, make sure that the connecting parts of the cooling fan motor connector are free of dirt, water or other foreign matter.
  • Be sure to securely connect the cooling fan motor connector.

(h) Engage the wire harness clamp.

(i) Connect the cooling fan motor connector.

(j) Engage the 4 clamps to connect the wire harness to the fan with motor assembly.

4. INSTALL NO. 3 INVERTER COOLING HOSE

(a) Install the No. 3 inverter cooling hose to the radiator assembly and slide the clip to secure it.

(b) Engage the clamp to connect the No. 3 inverter cooling hose to the fan with motor assembly.

5. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose to the radiator assembly and slide the clip to secure it.

(b) Engage the clamp to connect the No. 2 radiator hose to the fan with motor assembly.

6. CONNECT NO. 2 INVERTER COOLING HOSE

(a) Engage the clamp and connect the No. 2 inverter cooling hose to the fan with motor assembly.

7. CONNECT NO. 5 INVERTER COOLING HOSE

(a) Engage the 2 clamps and connect the No. 5 inverter cooling hose to the fan with motor assembly.

8. CONNECT NO. 4 INVERTER COOLING HOSE

(a) Connect the No. 4 inverter cooling hose to the radiator assembly and slide the clip to secure it.

9. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose to the radiator assembly and slide the clip to secure it.

(b) Engage the clamp to connect the No. 1 radiator hose to the fan with motor assembly.

10. CONNECT NO. 6 WATER BY-PASS HOSE

(a) Connect the No. 6 water by-pass hose to the radiator assembly.

11. CONNECT NO. 5 WATER BY-PASS HOSE

(a) Connect the No. 5 water by-pass hose to the radiator assembly and slide the clip to secure it.

12. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY

(a) Install the upper radiator support sub-assembly with the 4 bolts.

Torque:

12.5 N·m {127 kgf·cm, 9 ft·lbf}

(b) Engage the clamp to connect the hood lock control cable assembly to the upper radiator support sub-assembly.

13. INSTALL NO. 1 RADIATOR AIR GUIDE RH

(a) Engage the guide and claw.

(b) Install the No. 1 radiator air guide RH with the clip.

14. INSTALL NO. 1 RADIATOR AIR GUIDE LH

(a) Engage the guide and claw.

(b) Install the No. 1 radiator air guide LH with the clip.

15. INSTALL UPPER RADIATOR MOUNTING BRACKET

(a) Install the 2 upper radiator mounting brackets with the 2 bolts and 2 nuts.

Torque:

12.5 N·m {127 kgf·cm, 9 ft·lbf}

(b) Connect the 2 horn connectors.

16. INSTALL INLET AIR CLEANER ASSEMBLY

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17. INSTALL HOOD LOCK ASSEMBLY

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18. INSTALL RADIATOR SHUTTER SUB-ASSEMBLY

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19. INSTALL FRONT BUMPER REINFORCEMENT

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20. INSTALL FRONT BUMPER ENERGY ABSORBER

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21. INSTALL NO. 2 FRONT BUMPER ENERGY ABSORBER

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22. INSTALL HEADLIGHT ASSEMBLY

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23. INSTALL INVERTER WATER PUMP ASSEMBLY

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24. ADD ENGINE COOLANT (for Engine)

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25. INSPECT FOR COOLANT LEAK (for Engine)

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26. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

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27. INSTALL NO. 1 ENGINE UNDER COVER

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28. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

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29. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

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    Components

    On-vehicle Inspection

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