water pump TOYOTA AVENSIS 2002 Repair Manual

160N1±01
A78433
± COOLINGCOOLING SYSTEM (1AZ±FE)
16±13
AVENSIS REPAIR MANUAL (RM1018E)
COOLING SYSTEM (1AZ±FE)
ON±VEHICLE INSPECTION
1. INSPECT COOLING SYSTEM FOR LEAKS
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot. Ther-
mal expansion will cause hot engine coolant and steam to
blow out from the radiator.
(a) Remove the radiator support opening cover.
(b) Remove the engine room cover side.
(c) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(d) Warm up the engine.
(e) Pump it to 137 kPa (1.4 kgf/cm
2, 19.9 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator and water
pump for leaks. If there are no signs or traces of external coolant
leaks, check the heater core, cylinder block and head.
(f) Reinstall the engine room cover side.
(g) Reinstall the radiator support opening cover.
2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR
(a) The engine coolant should be between the ºLOWº and ºFULLº lines, when the engine is cold.
If low, check for leaks and add ºToyota Long Life Coolantº or equivalent up to the ºFULLº line.
3. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
(b) Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole;
the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

Radiator CapRadiator Cap Tester
30
or more
A51912
A36661
Turn 16±16
± COOLINGCOOLING SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(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.
NOTICE:
The following pump speed is for the first pump only (in or-
der to close the vacuum valve). After the first pump, the
pump speed can be reduced.
Pump speed: 1 push within 1 second
Standard opening pressure:
93 to 122 kPa (0.95 to 1.25 kgf/cm
2, 13.4 to 17.6 psi)
Minimum opening pressure:
78 kPa (0.8 kgf/cm
2, 11.2 psi)
If the opening pressure is less than minimum, replace the radia-
tor cap.
HINT:
Use the tester's maximum reading as the opening pressure.
3. INSPECT WATER PUMP ASSY
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and does not make noise.
If necessary, replace the water pump.

160MY±01
A78433
± COOLINGCOOLING SYSTEM (1AZ±FSE)
16±25
AVENSIS REPAIR MANUAL (RM1018E)
COOLING SYSTEM (1AZ±FSE)
ON±VEHICLE INSPECTION
1. INSPECT COOLING SYSTEM FOR LEAKS
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot. Ther-
mal expansion will cause hot engine coolant and steam to
blow out from the radiator.
(a) Remove the radiator support opening cover.
(b) Remove the engine room cover side.
(c) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(d) Warm up the engine.
(e) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator and water
pump for leaks. If there are no signs or traces of external coolant
leaks, check the heater core, cylinder block and head.
(f) Reinstall the engine room cover side.
(g) Reinstall the radiator support opening cover.
2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR
(a) The engine coolant should be between the ºLOWº and ºFULLº lines, when the engine is cold.
If low, check for leaks and add ºToyota Long Life Coolantº or equivalent up to the ºFULLº line.
3. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
(b) Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole;
the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

Radiator CapRadiator Cap Tester
30
or more
A51912
A36661
Turn 16±28
± COOLINGCOOLING SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(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.
NOTICE:
The following pump speed is for the first pump only (in or-
der to close the vacuum valve). After the first pump, the
pump speed can be reduced.
Pump speed: 1 push within 1 second
Standard opening pressure:
74 to 103 kPa (0.75 to 1.05 kgf/cm
2, 10.7 to 14.9 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm
2, 8.6 psi)
If the opening pressure is less than minimum, replace the radia-
tor cap.
HINT:
Use the tester's maximum reading as the opening pressure.
3. INSPECT WATER PUMP ASSY
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and does not make noise.
If necessary, replace the water pump.

160N6±01
A78434
Radiator Cap Tester
± COOLINGCOOLING SYSTEM (1CD±FTV)
16±37
AVENSIS REPAIR MANUAL (RM1018E)
COOLING SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
1. INSPECT COOLING SYSTEM FOR LEAKS
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot. Ther-
mal expansion will cause hot engine coolant and steam to
blow out from the radiator.
(a) Remove the radiator support opening cover.
(b) Remove the engine room cover side.
(c) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(d) Warm up the engine.
(e) Pump it to 137 kPa (1.4 kgf/cm
2, 19.9 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator and water
pump for leaks. If there are no signs or traces of external coolant
leaks, check the heater core, cylinder block and head.
(f) Reinstall the engine room cover side.
(g) Reinstall the radiator support opening cover.
2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR
(a) The engine coolant should be between the ºLOWº and ºFULLº lines, when the engine is cold.
If low, check for leaks and add ºToyota Long Life Coolantº or equivalent up to the ºFULLº line.
3. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
(b) Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole;
the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

B08802
Radiator Cap Tester
30
or
more Reserve tank Cap
A55603Drain Hole
Turn
16±40
± COOLINGCOOLING SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(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 reserve
tank cap.
(b) Pump the tester and measure the relief valve opening
pressure.
NOTICE:
The following pump speed is for the first pump only (in or-
der to close the vacuum valve). After the first pump, the
pump speed can be reduced.
Pump speed: 1 push within 1 second
Standard opening pressure:
93 to 122 kPa (0.95 to 1.25 kgf/cm
2, 13.4 to 17.6 psi)
Minimum opening pressure:
78 kPa (0.8 kgf/cm
2, 11.4 psi)
If the opening pressure is less than minimum, replace the re-
serve tank cap.
HINT:
Use the tester's maximum reading as the opening pressure.
3. INSPECT WATER PUMP ASSY
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and does not make noise.
If necessary, replace the water pump.

160N4±01
A79037
± COOLINGCOOLING SYSTEM (1ZZ±FE/3ZZ±FE)
16±1
AVENSIS REPAIR MANUAL (RM1018E)
COOLING SYSTEM (1ZZ±FE/3ZZ±FE)
ON±VEHICLE INSPECTION
1. INSPECT COOLING SYSTEM FOR LEAKS
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot. Ther-
mal expansion will cause hot engine coolant and steam to
blow out from the radiator.
(a) Remove the radiator support opening cover.
(b) Remove the engine room cover side.
(c) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(d) Warm up the engine.
(e) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator and water
pump for leaks. If there are no signs or traces of external coolant
leaks, check the heater core, cylinder block and head.
(f) Reinstall the engine room cover side.
(g) Reinstall the radiator support opening cover.
2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR
(a) The engine coolant level should be between the ºLOWº and ºFULLº lines, when the engine is cold.
If low, check for leaks and add ºToyota Long Life Coolantº or equivalent up to the ºFULLº line.
3. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
(b) Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole;
the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

Radiator CapRadiator Cap Tester
30
or more
A51912
A79816Hole
Turn 16±4
± COOLINGCOOLING SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(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.
NOTICE:
The following pump speed is for the first pump only (in or-
der to close the vacuum valve). After the first pump, the
pump speed can be reduced.
Pump speed: 1 push within 1 second
Standard opening pressure:
74 to 103 kPa (0.75 to 1.05 kgf/cm
2, 10.7 to 14.9 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm
2, 8.6 psi)
If the opening pressure is less than minimum, replace the radia-
tor cap.
HINT:
Use the tester's maximum reading as the opening pressure.
3. INSPECT WATER PUMP ASSY
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and does not make noise.
If necessary, replace the water pump.

160MW±01
B12054
SST
B12052
B12053
Pry
PryPry
±
COOLING WATER PUMP ASSY(1AZ±FE)
16±21
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1AZ±FE)
REPLACEMENT
1.DRAIN COOLANT (See page 16±19)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE ROOM COVER SIDE
4. REMOVE ENGINE UNDER COVER RH
5.REMOVE FAN AND GENERATOR V BELT (See page 14±105)
SST 09249±63010
6.REMOVE GENERATOR ASSY (See page 19±20)
7. REMOVE WATER PUMP PULLEY
(a) Using SST, remove 4 bolts and pump pulley.SST 09960±10010 (09962±01000, 09963±00700)
(b) Disconnect the crankshaft position sensor wire clamp from the water pump.
(c) Disconnect the crankshaft position sensor wire from the clamp on the water pump.
8. REMOVE WATER PUMP ASSY
(a) Remove 4 bolts, 2 nuts, wire clamp and water pump.
(b) Using a screwdriver, pry between the water pump and cyl- inder block, and remove the water pump.
NOTICE:
Be careful not to damage the contact surface of the water
pump and cylinder block.

A57664
Seal Width
2.2 to 2.5 mm0.5 to 1.0 mm
B12052
B12054
SST
16±22
±
COOLING WATER PUMP ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
9.INSTALL WATER PUMP ASSY
(a)Remove any old packing (FIPG) material from the con- tact surface.
(b)Apply seal packing to the water pump as shown in the il- lustration.
Seal packing: Part No. 08826 ± 00100 or equivalent

Install a nozzle that has been cut to a 2.2 to 2.5 mm
(0.09 to 0.10 in.) opening.

Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c)Install the water pump and wire clamp with 4 bolts and 2
nuts.
Torque: 9.0 N
m (90 kgf
cm, 80 in.
lbf)
(d)Install the crankshaft position sensor wire harness clamp to the water pump.
(e)Install the crankshaft position sensor wire to the wire clamp on the water pump.
10.INSTALL WATER PUMP PULLEY
(a)Using SST, install the pump pulley with 4 bolts. SST09960±10010 (09962±01000, 09963±00700)
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
11.INSTALL GENERATOR ASSY (See page 19±20)
12.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
13.ADD COOLANT (See page 16±19)
14.INSPECT CHECK FOR ENGINE COOLANT LEAKS (See page 16±17)