TOYOTA AVENSIS 2003 Service Repair Manual

Radiator CapRadiator Cap Tester
30

or more
A51912
A79816Hole
Turn
16±4
±
COOLING COOLING 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.
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160MV±01
A77341
Radiator Drain Cock Plug
Radiator Cap
Cylinder Bllock Drain Cock Plug Drain Pipe
±
COOLING ENGINE COOLANT (1AZ±FE)
16±19
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE COOLANT (1AZ±FE)
REPLACEMENT
1. DRAIN ENGINE COOLANT
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(a) Remove the radiator cap.
(b) Loosen the radiator plug and drain the coolant.
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16±20
±
COOLINGENGINE COOLANT(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
2.ADD ENGINE COOLANT
(a)Tighten the radiator drain plug, and pour coolant into radiator until it \
overflows. Capacity:
Transmission typeSteeringCoolant Capacity
[liters (US gts, lmp. gts)]
M/TLHD6.0 (6.3, 5.3)
M/TRHD6.1 (6.4, 5.4)
A/TLHD6.3 (6.7, 5.5)
A/TRHD6.4 (6.8, 5.6)
NOTICE:

Do not use an alcohol type coolant or plain water alone.

The coolant should be mixed with plain water (preferably demineralized wat\
er or distilled wa-
ter).
HINT:

Use of improper coolants may damage engine cooling system.

Use ºToyota Long Life Coolantº or equivalent and mix it with plain water ac\
cording to the manufactur-
er's directions.

Using of coolant with includes more than 50 % (freezing protection down to ±\
35C (±31F)) or 60 %
(freezing protection down to ±50C (±58F)) of ethylene±glycol is recommended but not more than
70 %.

Press the radiator inlet and outlet hose several times with hard.

If the coolant level gets lower, pour coolant.
(b)Reinstall the radiator cap.
(c)Pour engine coolant into the reservoir tank until it reaches full line.
(d)Warm up the engine until the thermostat valve begins to open.
HINT:
Press the radiator inlet and outlet hose several times with hard during \
the warming up.
(e)Stop the engine and wait until the coolant temp. Gets cold. Then remove the radiator cap to check the coolant level.
HINT:

If the level gets lower, perform the procedures above again.

If the level does not gets lower, adjust the reservoir tank coolant level.
3.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
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160MU±01
A77341
Radiator Drain Cock Plug
Radiator Cap
Cylinder Bllock Drain Cock Plug Drain Pipe
±
COOLING ENGINE COOLANT (1AZ±FSE)
16±31
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE COOLANT (1AZ±FSE)
REPLACEMENT
1. DRAIN ENGINE COOLANT
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(a) Remove the radiator cap.
(b) Loosen the radiator plug and drain the coolant.
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16±32
±
COOLINGENGINE COOLANT(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
2.ADD ENGINE COOLANT
(a)Tighten the radiator drain plug, and pour coolant into radiator until it \
overflows. Capacity:
Transmission typeSteeringCoolant Capacity
[liters (US gts, lmp. gts)]
M/TLHD6.0 (6.3, 5.3)
M/TRHD6.1 (6.4, 5.4)
A/TLHD6.3 (6.7, 5.5)
A/TRHD6.4 (6.8, 5.6)
NOTICE:

Do not use an alcohol type coolant or plain water alone.

The coolant should be mixed with plain water (preferably demineralized wat\
er or distilled wa-
ter).
HINT:

Use of improper coolants may damage engine cooling system.

Use ºToyota Long Life Coolantº or equivalent and mix it with plain water ac\
cording to the manufactur-
er's directions.

Using of coolant with includes more than 50 % (freezing protection down to ±\
35C (±31F)) or 60 %
(freezing protection down to ±50C (±58F)) of ethylene±glycol is recommended but not more than
70 %.

Press the radiator inlet and outlet hose several times with hard.

If the coolant level gets lower, pour coolant.
(b)Reinstall the radiator cap.
(c)Pour engine coolant into the reservoir tank until it reaches full line.
(d)Warm up the engine until the thermostat valve begins to open.
HINT:
Press the radiator inlet and outlet hose several times with hard during \
the warming up.
(e)Stop the engine and wait until the coolant temp. Gets cold. Then remove the radiator cap to check the coolant level.
HINT:

If the level gets lower, perform the procedures above again.

If the level does not gets lower, adjust the reservoir tank coolant level.
3.CHECK FOR ENGINE COOLANT LEAKS(See page 16±25)
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160MD±01
A79169
Water Drain
Plug
Radiator Drain Plug
A63951
AB
16±44
±
COOLING ENGINE COOLANT (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE COOLANT (1CD±FTV)
REPLACEMENT
1. DRAIN ENGINE COOLANT
(a) Remove the radiator cap.
(b) Loosen the radiator and engine drain plugs, drain the coolant.
(c) Close the drain plugs. Torque: 13 N
m (133 kgf
cm, 10 ft
lbf) for engine
2. ADD ENGINE COOLANT
(a) Loosen air bleed valve A.
(b) Fill the cooling system with coolant up to line B. Capacity:
With heater: 7.6 liters (8.0 US qts, 6.7 lmp. qts)
Without heater: 7.4 liters (7.8 US qts, 6.5 lmp. qts)
HINT:

Use of improper coolants may damage engine cooling
system.

Use ºToyota Long Life Coolantº or equivalent and mix it
with plain water according to the manufacturer's instruc-
tion.

Using of coolant which includes more than 50 % (freezing
protection down to ±35 C (±31 F)) or 60 % (freezing
protection down to ±50 C (±58 F)) of ethylene±glycol is
recommended but not more than 70 %.
(c) Tighten the air bleed valve securely.
(d) Install the radiator cap securely.
(e) Warm up the engine.
HINT:
Warm up the engine with the speed of 2,000 rpm or more and
keep the warm±up until the thermostat has open and the radia-
tor reservoir has become hot.
(f) Run the engine intermittently for 5 seconds at 3,000 rpm and for 45 seconds at idle.
(g) Do the above operation for 7 minutes or more.
(h) After the engine has become cold, check that the coolant level is between LOW and FULL lines.
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±
COOLING ENGINE COOLANT (1CD±FTV)
16±45
AVENSIS REPAIR MANUAL (RM1018E)
3. CHECK FOR ENGINE COOLANT LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tester.
(b) Pump it to 137 kPa (1.4 kgf/cm
2,
19.9 psi), and check that the pressure does not drop.
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160MH±01
A64364
Radiator CapCylinder Block
Drain Cock Plug
Drain Pipe
Radiator
Drain Cock Plug
±
COOLING ENGINE COOLANT (1ZZ±FE/3ZZ±FE)
16±7
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE COOLANT (1ZZ±FE/3ZZ±FE)
REPLACEMENT
1. DRAIN ENGINE COOLANT
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot.
Thermal expansion will cause hot engine coolant and
steam to blow out from the radiator.
(a) Remove the radiator cap.
(b) Loosen the radiator drain cock plug and the cylinder block
drain cock plug, and drain engine coolant.
(c) Close the radiator drain cock plug.
(d) Close the cylinder block drain plug. Torque: 13 N
m (130 kgf
cm, 9 ft
lbf) for engine
2. ADD ENGINE COOLANT
(a) Tighten the radiator drain plug, and pour coolant into radiator until it \
overflows. Capacity:
Transmission typeSteeringCoolant Capacity
[liters (US gts, lmp. gts)]
M/TLHD5.8 (6.1, 5.1)
M/TRHD5.9 (6.2, 5.2)
A/TLHD5.7 (6.0, 5.0)
A/TRHD5.8 (6.1, 5.1)
NOTICE:

Do not use an alcohol type coolant or plain water alone.

The coolant should be mixed with plain water (preferably demineralized wat\
er or distilled wa-
ter).
HINT:

Use of improper coolants may damage engine cooling system.

Use ºToyota Long Life Coolantº or equivalent and mix it with plain water ac\
cording to the manufactur-
er's instruction.

Using of coolant with includes more than 50 % (freezing protection down to ±\
35 C (±31 F)) or 60 %
(freezing protection down to ±50 C (±58 F)) of ethylene±glycol is recommended but not more than
70 %.

Press the radiator inlet and outlet hose several times by hand.

If the coolant level gets lower, pour coolant.
(b) Reinstall the radiator cap.
(c) Pour engine coolant into the reservoir tank until it reaches full line.
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16±8
±
COOLINGENGINE COOLANT(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(d)Warm up the engine until the thermostat valve begins to open.
HINT:
Press the radiator inlet and outlet hose several times by hand during th\
e warming up.
(e)Stop the engine and wait until the coolant temperature gets cold. Then remov\
e the radiator cap to check the coolant level.

If the level gets lower, perform the procedures from (a) through (e) again.

If the level does not gets lower, fill the reservoir tank with engine coolant.
3.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
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160MX±01
16±24
±
COOLINGRADIATOR ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
RADIATOR 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.DISCONNECT RADIATOR HOSE INLET
6.DISCONNECT RADIATOR HOSE OUTLET
7.REMOVE RADIATOR SUPPORT UPPER
(a)Disconnect the fan w/ motor wire harness, connector and the horn connect\
or.
(b)Remove 4 bolts, the nut and the radiator support.
8.REMOVE RADIATOR ASSY
(a)Remove 2 upper support, and radiator assembly
9.REMOVE RADIATOR SUPPORT LOWER
10.REMOVE FAN ASSY W/MOTOR
(a)Remove 6 bolts and fan w/motor.
11.INSTALL FAN ASSY W/MOTOR
12.INSTALL RADIATOR SUPPORT LOWER
13.INSTALL RADIATOR ASSY
14.INSTALL RADIATOR SUPPORT UPPER
(a)Install radiator support with 2 bolts. Torque: 19 N
m (194 kgf
cm,14 ft
lbf)
15.ADD COOLANT (See page 16±19)
16.INSPECT CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
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