2005 TOYOTA AVENSIS radiator

160MX±01
16±24
±
COOLING RADIATOR ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
RADIATOR ASSY(1AZ±FE)
REPLACEMENT
1.DRAIN COOLANT (See page 16±19)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER RH
5.DISCONNECT RADIATOR HOSE INLET
6.DISCONNECT RADIATOR HOSE OUTLET
7.REMOVE RADIATOR SUPPORT UPPER
(a)Disconnect the fan w/ motor wire harness, connector and the horn connect\
or.
(b)Remove 4 bolts, the nut and the radiator support.
8.REMOVE RADIATOR ASSY
(a)Remove 2 upper support, and radiator assembly
9.REMOVE RADIATOR SUPPORT LOWER
10.REMOVE FAN ASSY W/MOTOR
(a)Remove 6 bolts and fan w/motor.
11.INSTALL FAN ASSY W/MOTOR
12.INSTALL RADIATOR SUPPORT LOWER
13.INSTALL RADIATOR ASSY
14.INSTALL RADIATOR SUPPORT UPPER
(a)Install radiator support with 2 bolts. Torque: 19 N
m (194 kgf
cm,14 ft
lbf)
15.ADD COOLANT (See page 16±19)
16.INSPECT CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)

160MT±01
A56451
A77424
10
10

±
COOLING THERMOSTAT(1AZ±FE)
16±23
AVENSIS REPAIR MANUAL (RM1018E)
THERMOSTAT(1AZ±FE)
REPLACEMENT
1.DRAIN COOLANT(See page 16±19)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE FAN AND GENERATOR V BELT (See page 14±105)
SST09249±63010
6.REMOVE GENERATOR ASSY (See page 19±20)
7.REMOVE WATER INLET
(a)Remove 2 nuts, and disconnect the water inlet from thecylinder block.
8.REMOVE THERMOSTAT 9.INSTALL THERMOSTAT
(a)Install a new gasket to the thermostat.
(b)Install the thermostat with the jiggle valve upward.
HINT:
The jiggle valve may be set within 10
on either side of the pre-
scribed position.
10.INSTALL WATER INLET
(a)Install the water inlet with 2 nuts. Torque: 9.0 N
m (92 kgf
cm,7 in.
lbf)
11.INSTALL GENERATOR ASSY (See page 19±20)
12.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
13.ADD COOLANT (See page 16±19)
14.INSPECT CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)

160MW±01
B12054
SST
B12052
B12053
Pry
PryPry
±
COOLING WATER PUMP ASSY(1AZ±FE)
16±21
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1AZ±FE)
REPLACEMENT
1.DRAIN COOLANT (See page 16±19)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE ROOM COVER SIDE
4. REMOVE ENGINE UNDER COVER RH
5.REMOVE FAN AND GENERATOR V BELT (See page 14±105)
SST 09249±63010
6.REMOVE GENERATOR ASSY (See page 19±20)
7. REMOVE WATER PUMP PULLEY
(a) Using SST, remove 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.
8. REMOVE WATER PUMP ASSY
(a) Remove 4 bolts, 2 nuts, wire clamp and water pump.
(b) Using a screwdriver, pry between the water pump and cyl- inder block, and remove the water pump.
NOTICE:
Be careful not to damage the contact surface of the water
pump and cylinder block.

170FP±01
SST
A09582
17±22
±
LUBRICATION OIL PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE OIL(See page 17±30)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE FRONT WHEEL RH
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
7.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
8.REMOVE INJECTOR DRIVER(See page 14±307)
9.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
10.REMOVE GENERATOR V BELT (See page 14±269)
11.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
12.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
13.REMOVE CRANKSHAFT PULLEY(See page 14±307) SST09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
14.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
15.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
16.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
17.REMOVE TIMING BELT GUIDE
18.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
19.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
20.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
21.REMOVE TIMING BELT(See page 14±307)
22.REMOVE TIMING BELT IDLER SUB±ASSY NO.2(See page 14±307)
23.REMOVE CRANKSHAFT TIMING PULLEY
(a)If the timing pulley can not be removed by hand, use SSTto remove the pulley.
SST09950±50013 (09951±05010, 09952±05010, 09953±05010, 09953±05020, 09954±05021)
24.REMOVE GENERATOR ASSY(See page 19±29)
25. REMOVE TIMING BELT IDLER SUB±ASSY NO.1
26. REMOVE V±RIBBED BELT TENSIONER ASSY
(a) Remove the 2 bolts and the V±ribbed belt tensioner.

170FX±01
A77339
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
17±15
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1AZ±FSE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN ENGINE OIL
(a)Install a new gasket and drain plug after draining engine oil.
Torque: 25 N
m (250 kgf
cm,18 ft
lbf)
8.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
9.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
10.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±33)
11.SEPARATE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
12.REMOVE FUEL PUMP ASSY (See page 11±52)
13.REMOVE FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
14.REMOVE GENERATOR ASSY (See page 19±20)
15.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
16.SEPARATE VANE PUMP ASSY (See page 14±222)
17.SEPARATE RETURN TUBE SUB±ASSY (See page 14±222)
18. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) (See page 14±222)
19. SEPARATE VANE PUMP OIL RESERVOIR ASSY
20.REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14±222)
21. SEPARATE ENGINE WIRE
22.REMOVE COOLER BRACKET (LHD STEERING POSITION TYPE) (See page 14±222)
23. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(a) Remove a bolt and the engine service cover bracket RH.
24. REMOVE IGNITION COIL ASSY
(a) Remove 4 bolts and the ignition coils.
25.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
26.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±222)
27.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±222)
28.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±222)

170FU±01
A77281
17±8
±
LUBRICATION OIL PUMP ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1AZ±FE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN ENGINE OIL
(a)Install a new gasket and drain plug after draining engine oil. Torque: 25 N
m (250 kgf
cm,18 ft
lbf)
8.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
9.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
10.REMOVE GENERATOR ASSY (See page 19±20)
11.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
12.SEPARATE VANE PUMP ASSY (See page 14±139)
13.SEPARATE RETURN TUBE SUB±ASSY (See page 14±139)
14. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) (See page 14±139)
15. SEPARATE VANE PUMP OIL RESERVOIR ASSY
16.REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14±139)
17. SEPARATE ENGINE WIRE
18. REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a) Remove a bolt and the engine service cover bracket RH.
19.REMOVE COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE\
) (See
page 14±139)
20. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a) Remove a bolt and the engine service cover bracket RH.
21. REMOVE IGNITION COIL ASSY
(a) Remove 4 bolts and the ignition coils.
22.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
23.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
24.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
25.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±139)

160MG±01
±
COOLING RADIATOR ASSY(1CD±FTV)
16±51
AVENSIS REPAIR MANUAL (RM1018E)
RADIATOR ASSY(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE COOLANT(See page 16±44)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE RADIATOR RESERVE TANK ASSY(See page 16±50)
5.DISCONNECT RADIATOR HOSE INLET
6.DISCONNECT RADIATOR HOSE OUTLET
7.REMOVE RADIATOR ASSY
(a)Remove the 2 bolts and separate the relay box.
(b)Remove the 2 upper support and radiator assy.
8.REMOVE RADIATOR SUPPORT LOWER
9.REMOVE FAN ASSY W/MOTOR
(a)Remove the 2 bolts and the fan w/motor.
10.INSTALL FAN ASSY W/MOTOR
Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
11.INSTALL RADIATOR ASSY
(a)Install the 2 upper support and the radiator assembly to the vehicle. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
(b)Install the 2 bolts and the relay box.
Torque: 5.3 N
m (54 kgf
cm, 47 in.
lbf)
12.INSTALL RADIATOR RESERVE TANK ASSY(See page 16±50)
13.ADD ENGINE COOLANT(See page 16±44)
14.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)

160MF±01
A79171
A79172
10
10

16±50
±
COOLING THERMOSTAT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
THERMOSTAT(1CD±FTV)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE ENGINE ROOM COVER SIDE
3.DRAIN ENGINE COOLANT(See page 16±44)
4.REMOVE RADIATOR RESERVE TANK ASSY
(a)Disconnect the water by±pass hose No. 1 and water by±pass hose No.\
2.
(b)Remove the 2 bolts and the reserve tank assembly.
5.REMOVE RADIATOR HOSE OUTLET 6.REMOVE WATER INLET
(a)Remove the 2 bolts and the water inlet.
7.REMOVE THERMOSTAT 8.INSTALL THERMOSTAT
(a)Install a new gasket to the thermostat.
(b)Install the thermostat with the jiggle valve facing upward.
HINT:
The jiggle valve may be set within 10
on either side as shown
in the illustration.
9.INSTALL WATER INLET Torque: 8.8 N
m (90 kgf
cm,78 in.
lbf)
10.INSTALL RADIATOR RESERVE TANK ASSY
Torque: 6.0 N
m (61 kgf
cm,53 in.
lbf)
11.ADD ENGINE COOLANT(See page 16±44)
12.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)