2002 TOYOTA AVENSIS radiator

69067±02
B67410
± COMMUNICATION SYSTEMHIGH PITCHED HORN ASSY
69±5
AVENSIS REPAIR MANUAL (RM1018E)
HIGH PITCHED HORN ASSY
REPLACEMENT
1. REMOVE HIGH PITCHED HORN ASSY
(a) Disconnect the connector.
(b) Remove the bolt and horn.
2. INSTALL HIGH PITCHED HORN ASSY
(a) Place the stay onto the baffle part in the radiator support
upper, and then install the horn with the bolt.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(b) Connect the connector.

69068±02
B67411
69±4
± COMMUNICATION SYSTEMLOW PITCHED HORN ASSY
AVENSIS REPAIR MANUAL (RM1018E)
LOW PITCHED HORN ASSY
REPLACEMENT
1. REMOVE LOW PITCHED HORN ASSY
(a) Disconnect the connector.
(b) Remove the bolt and horn.
2. INSTALL LOW PITCHED HORN ASSY
(a) Place the stay onto the baffle part in the radiator support
upper, and then install the horn with the bolt.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(b) Connect the connector.

1606N±03
A57065
21


± COOLINGCOOLING FAN SYSTEM (1CD±FTV)
16±41
AVENSIS REPAIR MANUAL (RM1018E)
COOLING FAN SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83
C (181
F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
(c) Disconnect the temperature detect switch connector.
(d) Connect the terminals on the temperature detect switch connector.
(e) Check that the cooling fan rotates.
If not, check the fuses, cooling fan relay and cooling fan, and check for a open circuit between the cooling
fan relay and temperature detect switch.
(f) Reconnect the temperature detect switch connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 93
C (199
F))
(a) Start the engine, and raise coolant temperature to above 93
C (199
F)
HINT:
Coolant temperature is the detected value by the temperature detect switch on the radiator lower tank.
(b) Check that the cooling fan rotates.
If not, replace the temperature detect switch.
3. INSPECT COOLING FANS
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connec-
tor.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage:
Approx. 13.2 A at 20
C (68
F)
(d) Reconnect the cooling fan connector.

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)

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.

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.