TOYOTA AVENSIS 2003 Service Repair Manual
Manufacturer: TOYOTA, Model Year: 2003, Model line: AVENSIS, Model: TOYOTA AVENSIS 2003Pages: 2234, PDF Size: 56.95 MB
Page 871 of 2234
A73603
16±26
±
COOLING COOLING SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
4. INSPECT FINS BLOCKAGE
(a) If fins are clogged, wash them with water or a steam cleaner and dry with compressed air.
NOTICE:
If the distance between the steam cleaner and the
core is too close, there is a possibility of damaging
the fins, so keep the following injection distance.
Injection Pressures
kPa (kgf/cm2, psi)
Injection Distance mm (in.)
2,942 to 4,903
(30 to 50, 427 to 711)300 (11.811)
4,903 to 7,845
(50 to 80, 711 to 1,138)500 (19.685)
If the fins are bent, straighten them with a screwdriver
or pliers.
Be careful not pour water directly onto electronic
components.
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Page 872 of 2234
160MZ±01
P35001
P00436
10mm
A51911
±
COOLING COOLING SYSTEM (1AZ±FSE)
16±27
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT THERMOSTAT
HINT:
The thermostat is numbered with the valve opening tempera-
ture.
(a) Immerse the thermostat in water an gradually heat the
water.
(b) Check the valve opening temperature of the thermostat. Valve opening temperature:
86 to 90 C (187 to 198 F)
If the valve opening temperature is not as specified, replace the
thermostat.
(c) Check the valve lift. Valve lift: 10 mm (0.394 in.) or more at 100 C (212 F)
If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve is fully closed when the thermostat is at low temperatures (below 83 C (181 F)).
If not closed, replace the thermostat.
2. INSPECT RADIATOR CAP SUB±ASSY
NOTICE:
If the radiator cap is contaminatied, rinse it with water.
Before using a radiator cap tester, wet the relief valve
and the pressure valve with engine coolant or water.
When performing following steps (a) and (b), keep the
tester at an angle of over 30 above horizontal.
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Page 873 of 2234
Radiator CapRadiator Cap Tester
30
or more
A51912
A36661
Turn
16±28
±
COOLING COOLING 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.
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Page 874 of 2234
160N6±01
A78434
Radiator Cap Tester
±
COOLING COOLING 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 li\
nes, 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.
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Page 875 of 2234
A73603
16±38
±
COOLING COOLING SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
4. INSPECT FINS BLOCKAGE
(a) If fins are clogged, wash them with water or a steam cleaner and dry with compressed air.
NOTICE:
If the distance between the steam cleaner and the
core is too close, there is a possibility of damaging
the fins, so keep the following injection distance.
Injection Pressures
kPa (kgf/cm2, psi)
Injection Distance mm (in.)
2,942 to 4,903
(30 to 50, 427 to 711)300 (11.811)
4,903 to 7,845
(50 to 80, 711 to 1,138)500 (19.685)
If the fins are bent, straighten them with a screwdriver
or pliers.
Be careful not pour water directly onto electronic
components.
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Page 876 of 2234
160N7±01
B08008
CO0929
B08007
8.5mm
±
COOLING COOLING SYSTEM (1CD±FTV)
16±39
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT THERMOSTAT
HINT:
The thermostat is numbered with the valve opening tempera-
ture.
(a) Immerse the thermostat in water and gradually heat the
water.
(b) Check the valve opening temperature of the thermostat. Valve opening temperature:
80 to 84 C (176 to 183 F)
If the valve opening temperature is not as specified, replace the
thermostat.
(c) Check the valve lift. Valve lift: 8.5 mm (0.33 in.) or more at 95 C (203 F)
If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve is fully closed when the thermostat is at low temperatures (below 77 C (171 F)).
If not closed, replace the thermostat.
2. INSPECT RESERVE TANK CAP SUB±ASSY
NOTICE:
If the radiator cap is contaminatied, rinse it with water.
Before using a radiator cap tester, wet the relief valve
and the pressure valve with engine coolant or water.
When performing following steps (a) and (b), keep the
tester at an angle of over 30 above horizontal.
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Page 877 of 2234
B08802
Radiator Cap Tester
30 or
more
Reserve tank Cap
A55603Drain Hole
Turn
16±40
±
COOLING COOLING 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.
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Page 878 of 2234
160N4±01
A79037
±
COOLING COOLING 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.
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Page 879 of 2234
A73603
16±2
±
COOLING COOLING SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
4. INSPECT FINS BLOCKAGE
(a) If fins are clogged, wash them with water or a steam cleaner and dry with compressed air.
NOTICE:
If the distance between the steam cleaner and the
core is too close, there is a possibility of damaging
the fins, so keep the following injection distance.
Injection Pressures
kPa (kgf/cm2, psi)
Injection Distance mm (in.)
2,942 to 4,903
(30 to 50, 427 to 711)300 (11.811)
4,903 to 7,845
(50 to 80, 711 to 1,138)500 (19.685)
If the fins are bent, straighten them with a screwdriver
or pliers.
Be careful not pour water directly onto electronic
components.
http://vnx.su
Page 880 of 2234
160N5±01
P13560
P00436
P24125
10mm
±
COOLING COOLING SYSTEM (1ZZ±FE/3ZZ±FE)
16±3
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT THERMOSTAT
HINT:
The valve opening temperature is inscribed on the thermostat.
(a) Immerse the thermostat in water and gradually heat the
water.
(b) Check the valve opening temperature. Valve opening temperature:
80 to 84 C (176 to 183 F)
If the valve opening temperature is not as specified, replace the
thermostat.
(c) Check the valve lift. Valve lift: 10 mm (0.39 in.) or more at 95 C (203 F)
If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve is fully closed when the thermostat is at low temperatures (below 77 C (171 F)).
If not closed, replace the thermostat.
2. INSPECT RADIATOR CAP SUB±ASSY
NOTICE:
If the radiator cap is contaminatied, rinse it with water.
Before using a radiator cap tester, wet the relief valve
and the pressure valve with engine coolant or water.
When performing following steps (a) and (b), keep the
tester at an angle of over 30 above horizontal.
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