TOYOTA AVENSIS 2005 Service Repair Manual

160MV±01
A77341
Radiator Drain Cock Plug Radiator Cap
Cylinder Bllock Drain Cock Plug
Drain Pipe
± COOLINGENGINE 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.

16±20
±
COOLING ENGINE 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 ±\
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 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)

160N3±01
E34090
A30519
E34090
16±18
± COOLINGCOOLING FAN SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT COOLING FAN RELAY
(a) Continuity inspection.
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)
2. INSPECT COOLING FAN RELAY NO.2
(a) Continuity inspection.
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2
3 ± 4Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)
3. INSPECT COOLING FAN RELAY NO.3
(a) Continuity inspection.
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)

1600R±13
± COOLINGCOOLING FAN SYSTEM (1AZ±FE)
16±17
AVENSIS REPAIR MANUAL (RM1018E)
COOLING FAN SYSTEM (1AZ±FE)
ON±VEHICLE INSPECTION
HINT:
It is normal that the cooling fan sometime rotates when the ignition switch is turned from ACC to ON.
1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 77
C (171
F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and engine coolant temperature sensor, and check for disconnection of
connectors or wire break between the cooling fan relay and engine coolant temperature sensor.
(c) Disconnect the engine coolant temperature sensor connector.
(d) Check that the cooling fan rotates.
If not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short circuit between the
cooling fan relay and engine coolant temperature sensor.
(e) Reconnect the engine coolant temperature sensor connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 95.5
C (204
F))
(a) Start the engine, and raise coolant temperature to above 95.5
C (204
F).
HINT:
Coolant temperature is the detected value by the engine coolant temperature sensor on the water outlet.
(b) Check that the cooling fan rotates.
If not, replace the engine coolant temperature sensor.
3. INSPECT COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Standard amperage:
5.2 to 8.2 A at 20
C (68
F) (M/T)
8.3 to 11.3 A at 20
C (68
F) (A/T)
(d) Reconnect the cooling fan connector.
4. INSPECT COOLING FAN No.2 (With Air Conditioner)
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Standard amperage:
5.2 to 8.2 A at 20
C (68
F) (M/T)
8.3 to 11.3 A at 20
C (68
F) (A/T)
(d) Reconnect the cooling fan connector.

160N2±01
P13560
P00436
10mm
A51911
± COOLINGCOOLING SYSTEM (1AZ±FE)
16±15
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 84C (176 to 183F)
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 95C (203F)
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 77C (171F)).
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.

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.

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.

A73603
16±14
± COOLINGCOOLING SYSTEM (1AZ±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.

160MK±01
A76724
A79300Upper Hook
±
COOLING RADIATOR ASSY(1ZZ±FE/3ZZ±FE)
16±11
AVENSIS REPAIR MANUAL (RM1018E)
RADIATOR ASSY(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
2.REMOVE ENGINE ROOM COVER SIDE (See page 14±27)
3.ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
4.DRAIN ENGINE COOLANT (See page 16±1)
5. DISCONNECT RADIATOR HOSE INLET
(a) Disconnect the radiator hose inlet from the radiator.
6. DISCONNECT RADIATOR HOSE OUTLET
(a) Disconnect the radiator hose outlet from the radiator.
7. DISCONNECT OIL COOLER INLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler inlet tube from the radiator.
8. DISCONNECT OIL COOLER OUTLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler outlet tube from the radiator.
9. REMOVE RADIATOR ASSY
(a) Disconnect the fan connector and the 2 harness clamps.
(b) Remove the 2 bolts and the relay block.
(c) Remove the 2 bolts, the 2 radiator support upper and theradiator.
(d) Remove the 2 support radiator LWRs from the radiator.
(e) Pinch and push each upper hook on the fan shroud to re- lease and remove the fan shroud from the radiator.

A79301
Upper Hook
Fan
Shroud
Radiator
16±12
±
COOLING RADIATOR ASSY(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
10.INSTALL RADIATOR ASSY
(a)Align the 2 keyways of the fan shroud with the 2 keys lo- cated on the lower bottom of the radiator and fit them.
(b)Install the fan should to the radiator with the 2 upper hooks. You can hear ºclickº sounds when the hooks are
securely fitted.
(c)Install the 2 support radiator LWRs to the radiator.
(d)Install the radiator with the 2 bolts and 2 radiator support
uppers.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
(e)Install the relay block with the 2 bolts.
(f)Connect the fan connector and 2 harness clamps.
11.ADD ENGINE COOLANT (See page 16±7)
12.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)