2005 TOYOTA AVENSIS 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.

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.

160MH±01
A64364
Radiator CapCylinder Block
Drain Cock Plug
Drain Pipe
Radiator
Drain Cock Plug
± COOLINGENGINE COOLANT (1ZZ±FE/3ZZ±FE)
16±7
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE COOLANT (1ZZ±FE/3ZZ±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.
Thermal expansion will cause hot engine coolant and
steam to blow out from the radiator.
(a) Remove the radiator cap.
(b) Loosen the radiator drain cock plug and the cylinder block
drain cock plug, and drain engine coolant.
(c) Close the radiator drain cock plug.
(d) Close the cylinder block drain plug.
Torque: 13 N
m (130 kgf
cm, 9 ft
lbf) for engine
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/TLHD5.8 (6.1, 5.1)
M/TRHD5.9 (6.2, 5.2)
A/TLHD5.7 (6.0, 5.0)
A/TRHD5.8 (6.1, 5.1)
NOTICE:

Do not use an alcohol type coolant or plain water alone.

The coolant should be mixed with plain water (preferably demineralized water 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 according to the manufactur-
er's instruction.

Using of coolant with includes more than 50 % (freezing protection down to ±35C (±31F)) or 60 %
(freezing protection down to ±50C (±58F)) of ethylene±glycol is recommended but not more than
70 %.

Press the radiator inlet and outlet hose several times by hand.

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.

16±8
±
COOLING ENGINE COOLANT(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(d)Warm up the engine until the thermostat valve begins to open.
HINT:
Press the radiator inlet and outlet hose several times by hand during th\
e warming up.
(e)Stop the engine and wait until the coolant temperature gets cold. Then remov\
e the radiator cap to check the coolant level.

If the level gets lower, perform the procedures from (a) through (e) again.

If the level does not gets lower, fill the reservoir tank with engine coolant.
3.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)

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.

Radiator CapRadiator Cap Tester
30
or more
A51912
A79816Hole
Turn 16±4
± COOLINGCOOLING SYSTEM (1ZZ±FE/3ZZ±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:
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.

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.