water pump TOYOTA AVENSIS 2003 Service Repair Manual

010BA±14
01±42
±
INTRODUCTION TERMS
AVENSIS REPAIR MANUAL (RM1018E)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this ma\
nual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI/INJ)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Communication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Trouble Code
DTMDiagnostic Test Mode±
ECLEngine Control Level±
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionDistributorless Ignition (DLI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control±
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory±
FEPROMFlash Erasable Programmable Read Only Memory±
FFFlexible Fuel±
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)
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022KA±01
02±18
±
PREPARATION COOLING
AVENSIS REPAIR MANUAL (RM1018E)
COOLING
PREPARATION
SST
09023±12700Union Nut Wrench 17mmWATER PUMP ASSY(1CD±FTV)
09213±54015Crankshaft Pulley Holding ToolWATER PUMP ASSY(1CD±FTV)
(90105±08076)BoltWATER PUMP ASSY(1CD±FTV)
09249±63010Torque Wrench AdaptorWATER PUMP ASSY(1AZ±FE)
THERMOSTAT(1AZ±FE)
WATER PUMP ASSY(1AZ±FSE)
THERMOSTAT(1AZ±FSE)
09330±00021Companion Flange Holding ToolWATER PUMP ASSY(1CD±FTV)
09950±50013Puller C SetWATER PUMP ASSY(1CD±FTV)
(09951±05010)Hanger 150WATER PUMP ASSY(1CD±FTV)
(09952±05010)Slide ArmWATER PUMP ASSY(1CD±FTV)
(09953±05020)Center Bolt 150WATER PUMP ASSY(1CD±FTV)
(09954±05021)Claw No.2WATER PUMP ASSY(1CD±FTV)
(09954±05031)Claw No.3WATER PUMP ASSY(1CD±FTV)
09960±10010Variable Pin Wrench SetWATER PUMP ASSY(1AZ±FE)
WATER PUMP ASSY(1AZ±FSE)
WATER PUMP ASSY(1CD±FTV)
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±
PREPARATION COOLING
02±19
AVENSIS REPAIR MANUAL (RM1018E)
(09962±01000)Variable Pin Wrench Arm AssyWATER PUMP ASSY(1AZ±FE)
WATER PUMP ASSY(1AZ±FSE)
WATER PUMP ASSY(1CD±FTV)
(09963±00700)Pin 7WATER PUMP ASSY(1AZ±FE)
WATER PUMP ASSY(1AZ±FSE)
(09963±01000)Pin 10WATER PUMP ASSY(1CD±FTV)
Recomended Tools
09216±00021Belt Tension GaugeWATER PUMP ASSY(1CD±FTV)
Equipment
Hexagon wrench (8mm)
Ohmmeter
Radiator cap tester
Thermometer
Torque wrench
Slide calipers
Wooden block
Heater
SSM
08826±00080Seal Packing Black or equivalent
(FIPG)WATER PUMP ASSY(1AZ±FE)
WATER PUMP ASSY(1AZ±FSE)
WATER PUMP ASSY(1CD±FTV)
Coolant
ItemCapacityClassification
Engine coolant (3ZZ±FE)
Left±hand drive vehicles
Right±hand drive vehicles
5.8 liters (6.1 US qts, 5.1 lmp. qts)
5.9 liters (6.2 US qts, 5.2 lmp. qts)
TOYOTA long life coolant
Engine coolant (1ZZ±FE)
Left±hand drive vehicles M/T
A/T
Right±hand drive vehicles M/T A/T
5.8 liters (6.1 US qts, 5.1 lmp. qts)
5.7 liters (6.0 US qts, 5.0 lmp. qts)
5.9 liters (6.2 US qts, 5.2 lmp. qts)
5.8 liters (6.1 US qts, 5.1 lmp. qts)
TOYOTA long life coolant
Engine coolant (1AZ±FE/1AZ±FSE)
Left±hand drive vehicles M/TA/T
Right±hand drive vehicles M/T A/T
6.0 liters (6.3 US qts, 5.3 lmp. qts)
6.3 liters (6.7 US qts, 5.5 lmp. qts)
6.1 liters (6.4 US qts, 5.4 lmp. qts)
6.4 liters (6.8 US qts, 5.6 lmp. qts)
TOYOTA long life coolant
Engine coolant (1CD±FTV)w/ power heater
w/o power heater
7.6 liters (8.0 US qts, 6.7 lmp. qts)
7.4 liters (7.8 US qts, 6.5 lmp. qts)
TOYOTA long life coolant
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02±6
±
PREPARATION FUEL
AVENSIS REPAIR MANUAL (RM1018E)
09082±00040TOYOTA Electrical TesterFUEL SYSTEM(1CD±FTV)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
(09083±00150)Test Lead SetFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1AZ±FSE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
09130±00150Water Pump PliersFUEL FILTER ASSY(1CD±FTV)
09216±00021Belt Tension GaugeINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
Equipment
Clip
Hexagon wrench (6 mm)
Measuring Flask
Ohmmeter
Radiator cap tester
Service Wire Harness
Stopwatch
Torque wrench
Vernier calipers
Wooden block
SSM
08826±00080Seal Packing Black or equivalent
(FIPG)INJECTOR ASSY(1CD±FTV)
08850±00065Butyl Tape SetFUEL TANK ASSY(DIESEL)
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031H4±01
03±26
±
SERVICE SPECIFICATIONS COOLING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Radiator drain plug131309
Water pump x Cylinder block Bolt A
Bolt B9.0 1192
11 38.0 in.lbf 8
Water inlet x Cylinder block sub±assy1111 28
Radiator x Radiator support upper1919414
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Water pump x Cylinder block9.09280 in.
lbf
Water pump x Water pump pulley2626519
Water inlet x Cylinder block9.09280 in.
lbf
Radiator support upper x body1919414
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Water pump x Cylinder block9.09280 in.
lbf
Water pump x Water pump pulley2626519
Water inlet x Cylinder block9.09280 in.
lbf
Radiator support upper x body1919414
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Drain plug1313310
Water pump x Cylinder block3132023
Fuel inlet pipe sub±assy x Common rail assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe sub±assy x Injection pump Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Timing belt idler Sub±assy No.1 x Cylinder block3535726
Water inlet x Cylinder block8.89078 in.
lbf
Radiator reserve tank assy x Radiator assy6.06153 in.
lbf
Fan assy w/ motor x Fan shroud assy7.57666 in.
lbf
Upper support x Body1919414
Relay box x Radiator assy5.35447 in.
lbf
Front wheel1031,05076
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03±18
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ft
lbf
kgf
cm
N
m
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder head1515311
Water by±pass pipe No.1 x Cylinder block9.09280 in.
lbf
Drive shaft bearing bracket x Cylinder block5455140
Oil level gauge guide x Cylinder block9.09280 in.
lbf
V±ribbed belt tensioner assy x Timing chain cover6060744
Ignition coil assy x Cylinder head9.09280 in.
lbf
Water inlet x Cylinder block9.09280 in.
lbf
Exhaust manifold converter x Cylinder head3737827
Exhaust manifold stay x Exhaust manifold converter4444932
Manifold converter insulator No. 1 x Exhaust manifold converter121229
Surge tank stay No. 1 x Intake manifold2121015
Intake manifold x Cylinder head3030622
Throttle Body bracket x Throttle body2121015
Fly wheel (M/T) x Crank shaft1301,32796
Drive plate & ring gear (A/T) x Crankshaft981,00072
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front8788764
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Front suspension cross member sub±assy front x Body Front
Rear45
133459
1,35633
98
Front suspension brace RH x Frame Bolt A
Bolt B133 801,356 81698
59
Front suspension brace LH x Frame Bolt A
Bolt B133
801,356 81698
59
Transverse engine engine mounting insulator LH x Engine mounting bracket
LH8788764
Transverse engine engine mounting insulator RH x Engine mounting bracket
RH5253038
Engine mounting bracket x No, 2 RH x Transverse engine
engine mounting insulator A B
52
11 3530
1,15238
83
Clutch release cylinder x manual transaxle Bolt A
Bolt B
Bolt C12
9.0
5.0122 92
5189
80 in.
lbf
44 in.
lbf
Vane pump assy x Timing chain cover4343931
Front suspension arm sub±assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body RHD steering position type9.09280 in.
lbf
Cooler bracket x Body LHD steering position type9.09280 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Return tube sub±assy x Frame8.08271 in.
lbf
Radiator reserve tank x sub±assy x body5.05144 in.
lbf
Compressor and magnetic clutch x Cylinder block2525518
Radiator relay block x Frame5.05144 in.
lbf
Engine cover No. 1 x Cylinder head cover7.07162 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head x Cylinder block 1st
2nd79
Turn 90
806
Turn 90
58
Turn 90

Camshaft timing control valve assy x Cylinder head9.09280 in.
lbf
Camshaft timing gear assy x Camshaft5455140
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±
SERVICE SPECIFICATIONSENGINE MECHANICAL
03±19
AVENSIS REPAIR MANUAL (RM1018E) Part Tightenedft
lbf
kgf
cm
N
m
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.
lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.
lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.
lbf
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14±222)Bolt A
Bolt B
Bolt C Nut9.021
43
9.092
214
438 9280 in.
lbf
15
32
80 in.
lbf
Oil pan x Stiffening crankcase assy9.09280 in.
lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Idle pulley set nut3839028
Air tube No. 1 x Air tube No. 22525518
Air tube No. 1 x Intake air connector2525518
Air tube No. 1 x Cylinder head sub±assy2525518
Air tube No. 1 x Engine mounting bracket FR2525518
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Front wheel1031,05076
Drain plug (Manual transaxle)4950036
Engine hanger No.1 x Cylinder head3737727
Engine hanger No.2 x Cylinder head3737727
Engine hanger No. 1 UPR x Engine hanger No. 13737727
Engine coolant temperature sensor x Cylinder head2020415
Crankshaft position sensor x Oil pump assy8.89078 in.
lbf
Camshaft position sensor x Camshaft oil seal retainer8.89078 in.
lbf
Fuel filler to injection pump fuel pipe x Cylinder block M6 and Nut
M88.82190
20978 in.
lbf
15
Oil cooler pipe x Cylinder block5960043
Compressor mounting bracket x Cylinder block4242831
Injection pump x Water pump2121415
Oil level gage guide x Cylinder block1818413
Timing belt No.3 cover x Cylinder head7.47565 in.
lbf
Intake manifold x Cylinder head2121415
Wiring harness clamp bracket x Intake manifold3.9 to 6.940 to 7035 to 61 in.
lbf
Power steering idle pulley bracket x Cylinder head Bolt A
Bolt B72
39734
39853
29
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
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03±20
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ft
lbf
kgf
cm
N
m
Injection pipe, Fuel inlet pipe x Common rail
Used pipe using SST
Used pipe not using SST New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Injection pipe x Injector Used pipe using SST
Used pipe not using SST New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Injection pipe clamp x Intake manifold5.05144 in.
lbf
Fuel inlet pipe x Common rail
Used pipe using SST
Used pipe not using SST New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe x injection pump Used pipe using SST
Used pipe not using SST New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Nozzle leakage pipe No.2 x Cylinder head Check valve
Bolt21
8.8214 9015
78 in.
lbf
Vacuum pump x Cylinder head2121415
EGR valve assy x Cylinder head1818413
Intake air connector with diesel throttle body x Intake manifold2121415
Water inlet x Cylinder block8.89078 in.
lbf
Water outlet sub±assy x Cylinder head2121415
Exhaust manifold x Cylinder head4747935
EGR pipe sub±assy x Cylinder head Bolt
Nut37
25375
25027
18
Oil filter bracket x Oil pan sub±assy3434725
V±ribbed belt tensioner assy x Oil pump3131623
Generator bracket No.1 x Cylinder block3737727
Idler pulley Sub±assy x V±ribbed belt tensioner assy4040830
Engine mounting bracket RR x Engine mounting insulator RR6465347
Engine mounting bracket FR x Engine mounting insulator FR6465347
Drive shaft bearing bracket x Cylinder block6465347
Rear end plate x Cylinder block8.48674 in.
lbf
Flywheel x Crankshaft7172052
Engine mounting member sub±assy center x Body4545933
Front suspension crossmember sub±assy x Rear engine mounting bracket8788764
Front suspension crossmember sub±assy x Front engine mounting bracket\
5253038
Front suspension crossmember sub±assy x Body1331,35698
Front suspension member brace x Front suspension crossmember sub±assy\
1331,35698
Front suspension member brace x Body8081659
Return tube sub±assy x Body8.08271 in.
lbf
Engine mounting insulator RH x Body5253038
Engine mounting bracket LH x Engine mounting insulator LH8081659
Injector driver x Engine mounting insulator RH5.05144 in.
lbf
Engine wire x Body8.48574 in.
lbf
Air tube No.2 x Manual transaxle2525518
Relay box x Radiator assy5.35446 in.
lbf
Fuel filter assy x Fuel filter support1817813
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±
SERVICE SPECIFICATIONS FUEL
03±9
AVENSIS REPAIR MANUAL (RM1018E)Part Tightened
ft
lbf
kgf
cm
N
m
Injection pipe clamp No. 2 x Intake manifold5.05144 in.
lbf
Fuel inlet pipe sub±assy x Common rail assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe sub±assy x Injection pump assy Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Air cleaner case x Body7.07162 in.
lbf
Air cleaner case x Transverse engine engine mounting bracket7.07162 in.
lbf
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Vacuum reservoir sub±assy x Cowl top panel outer8.38574 in.
lbf
Injection pump assy x Water pump assy2121015
Injection pump drive pulley x Injection pump assy6465047
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
Common rail assy x Cylinder head sub±assy4343832
Transverse engine engine mounting bracket x Water pump assy6465047
Transverse engine engine mounting bracket x Cylinder block sub±assy3737527
Idler pulley sub±assy x V±ribbed belt tensioner assy4040830
Battery clamp sub±assy x Body5.05144 in.
lbf
Front wheel1031,05076
Fuel filter assy x Fuel filter support1817813
DIESEL:
Part TightenedN
mkgf
cmft
lbf
Fuel tank band sub±assy x Body4040029
Parking brake cable assy x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Fuel tank band sub±assy No. 15.45548 in.
lbf
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031FR±02
03±12
±
SERVICE SPECIFICATIONS INTAKE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Turbo water pipe sub±assy No.1 x Turbocharger sub±assy131359.7
Turbocharger sub±assy x Exhaust manifold5354039
Turbo oil outlet pipe x Turbocharger sub±assy131359.7
Manifold converter sub±assy x Turbocharger sub±assy 1st
2nd8.0
2582
25571 in.
lbf
18
Manifold stay x Manifold converter sub±assy 1st
2nd8.0
6182
62271 in.
lbf
45
Manifold stay x Cylinder block sub±assy 1st
2nd8.0
6182
62271 in.
lbf
45
Turbohcharger stay x Turbocharger sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Turbocharger stay x Cylinder head sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Manifold stay No. 2 x Manifold converter sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Manifold stay No. 2 x Cylinder head sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Exhaust manifold heat insulator No. 2 x Turbocharger sub±assy121228.9
Turbo insulator No. 1 x Manifold converter sub±assy2020415
Turbo insulator No. 1 x Turbocharger sub±assy2020415
Turbo insulator No. 2 x Manifold converter sub±assy2020415
Exhaust pipe assy x Heater bracket sub±assy w/ Cold area7.57666 in.
lbf
Exhaust pipe assy x Body w/ Cold area7.57666 in.
lbf
Heater bracket x Body w/ Cold area7.57666 in.
lbf
Heater pump assy x Heater bracket w/ Cold area7.57666 in.
lbf
Air tube No. 1 x Air tube No. 22525518
Air tube No. 1 x Intake air connector2525518
Air tube No. 1 x Cylinder head cover2525518
Air tube No. 1 x Engine mounting bracket FR2525518
Air cleaner case x Body7.07162 in.
lbf
Intercooler assy x Body7.07162 in.
lbf
Intercooler cooling air duct x Intercooler assy5.05144 in.
lbf
Air cleaner case x Engine mounting insulator LH7.07162 in.
lbf
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Vacuum reservoir sub±assy x Cowl top panel outer8.38573 in.
lbf
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