cooling TOYOTA AVENSIS 2005 Service Manual Online

031H3−02
03−20
− SERVICE SPECIFICATIONSCOOLING
AVENSIS Supplement (RM1045E)
COOLING
SERVICE DATA
2AZ−FSE:
Thermostat
Valve opening temperature
Valve lift at 95_C (203_F)
80 to 84_C (176 to 183_F)
10 mm (0.394 in.) or more
Radiator cap sub−assy
Standard opening pressure
74 to 103 kPa (0.75 to 1.05 kgf/cm2, 10.7 to 14.9 psi)
Cooling fan
Standard amperage at 20_C (68_F)
Standard amperage (No. 2) at 20_C (68_F)
8.5 to 11.5 A
5.2 to 8.2 A
Cooling fan relay
Specified condition Between terminals 3 and 5
Cooling fan relay No. 2
Specified condition Between terminals 3 and 4
Between terminals 3 and 5
Cooling fan relay No. 3
Specified condition Between terminals 3 and 5
10 k
or higher
Below 1
(Apply battery voltage terminals 1 and 2)
Below 1

10 k
or higher (Apply battery voltage terminals 1 and 2)
10 k
or higher
Below 1
(Apply battery voltage terminals 1 and 2)
10 k
or higher
Below 1
(Apply battery voltage terminals 1 and 2)
1CD−FTV:
Thermostat
Valve opening temperature
Valve lift at 95_C (203_F)
80 to 84_C (176 to 183_F)
8.5 mm (0.335 in.) or more
Radiator cap sub−assy
Standard opening pressure
Minimum opening pressure
93 to 122 kPa (0.95 to 1.25 kgf/cm2, 13.4 to 17.6 psi)
78 kPa (0.8 kgf/cm2, 11.4 psi)

A61173
B A
TA C
A52006
A09593
SST
(Attachment) 14−88
− ENGINE MECHANICALENGINE (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(b) Inspect the generator V−ribbed belt.
(1) Check that the tension indicator is within range A on
the auto tensioner scale.
If the tension indicator is not within range A, replace the belt with
a new one.
HINT:
When replacing the drive belt with a new one, the tension indi-
cator should be within range B.
6. INSPECT ENGINE IDLE SPEED
(a) Using SST, connect a tachometer test probe to terminal
9 (TAC) of the DLC3.
SST 09843−18040
(b) Check the idle speed.
Idle speed: 750 to 850 rpm
NOTICE:
SCheck the idle speed with the cooling fan OFF.
SSwitch OFF all accessories and air conditioning be-
fore connecting the test probe to the terminal.
7. INSPECT MAXIMUM SPEED
(a) Start the engine.
(b) Fully depress the accelerator pedal.
(c) Check the maximum speed.
Maximum speed: 5,100 to 5,250 rpm
8. INSPECT COMPRESSION
(a) Warm up the engine to the normal operating temperature,
then stop the engine.
(b) Remove the 4 glow plugs
(see Pub. No. RM1018E on page 19−33).
(c) Disconnect the 4 injector connectors.
(d) Inspect the cylinder compression pressure.
(1) Install SST (an attachment) to the glow plug hole.
SST 09992−00025 (09992−00121, 09992−00211)
Torque: 12 N
m (125 kgf
cm, 95 ft
lbf)

160MQ−02
A56451
A77424
10 _10_
Jiggle Valve
16 −14
−
COOLING THERMOSTAT (2AZ −FSE)
AVENSIS Supplement (RM1045E)
THERMOSTAT (2AZ −FSE)
REPLACEMENT
1. DRAIN COOLANT (See page 16 −7)
2. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14 −23)
3. REMOVE ENGINE ROOM COVER SIDE (See page 14 −23)
4. REMOVE ENGINE UNDER COVER LH (See page 14 −23)
5. REMOVE ENGINE UNDER COVER NO.4 RH (See page 14 −23)
6. REMOVE ENGINE UNDER COVER RH (See page 14 −23)
7. REMOVE FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
8. REMOVE GENERATOR ASSY (See page 19 −8)
9. REMOVE WATER INLET
(a) Remove the 2 nuts and water inlet.
10. REMOVE THERMOSTAT 11. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Install the thermostat while aligning the jiggle valve withits right position described in the illustration.
HINT:
The jiggle valve may be set within 10 _ of either side of the pre-
scribed position.
12. INSTALL WATER INLET Torque: 9.0 N
m (92 kgf
cm, 7 in.
lbf)
13. INSTALL GENERATOR ASSY (See page 19 −8)
14. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
15. ADD COOLANT (See page 16 −7)
16. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)

160MR−02
B12054
SST
B12052
B12053
Pry
PryPry
16
−12
−
COOLING WATER PUMP ASSY (2AZ −FSE)
AVENSIS Supplement (RM1045E)
WATER PUMP ASSY (2AZ −FSE)
REPLACEMENT
1. DRAIN COOLANT (See page 16 −7)
2. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14 −23)
3. REMOVE ENGINE ROOM COVER SIDE (See page 14 −23)
4. REMOVE ENGINE UNDER COVER LH (See page 14 −23)
5. REMOVE ENGINE UNDER COVER NO.4 RH (See page 14 −23)
6. REMOVE ENGINE UNDER COVER RH (See page 14 −23)
7. REMOVE FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
8. REMOVE GENERATOR ASSY (See page 19 −8)
9. REMOVE WATER PUMP PULLEY
(a) Using SST, remove the 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.
10. REMOVE WATER PUMP ASSY
(a) Remove the 4 bolts, 2 nuts, wire clamp and water pump.
(b) Using a screwdriver, pry out between the water pump and cylinder 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
−
COOLING WATER PUMP ASSY (2AZ −FSE)
16 −13
AVENSIS Supplement (RM1045E)
11. INSTALL WATER PUMP ASSY
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water
pump assy.
(b) Apply a continuous bead of the seal packing (diameter 2.2 to 2.5 mm (0.09 to 0.10 in.)) as shown in the illustra-
tion.
Seal packing: Part No. 08826 − 00100 or equivalent
NOTICE:
Install the water pump assy within 5 minutes after applying
seal packing. Otherwise the material must be removed and
reapplied.
(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) I nst all t he cr ankshaf t posit ion s ensor wir e t o t he wir e clamp on the water pump.
12. INSTALL WATER PUMP PULLEY
(a) Using SST, install the pump pulley with 4 bolts. SST 09960 −10010 (09962 −01000, 09963 −00700)
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
13. INSTALL GENERATOR ASSY (See page 19 −8)
14. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
15. ADD COOLANT (See page 16 −7)
16. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)