2002 TOYOTA AVENSIS Repair Manual

Radiator CapRadiator Cap Tester
30
or more
A51912
A36661
Turn 16±28
± COOLINGCOOLING 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.

160N6±01
A78434
Radiator Cap Tester
± COOLINGCOOLING 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 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±38
± COOLINGCOOLING 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.

160N7±01
B08008
CO0929
B08007
8.5mm
± COOLINGCOOLING 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 84C (176 to 183F)
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 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 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.

B08802
Radiator Cap Tester
30
or
more Reserve tank Cap
A55603Drain Hole
Turn
16±40
± COOLINGCOOLING 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.

160N4±01
A79037
± COOLINGCOOLING 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.

A73603
16±2
± COOLINGCOOLING 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.

160N5±01
P13560
P00436
P24125
10mm
± COOLINGCOOLING 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 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 (0.39 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.