2005 TOYOTA AVENSIS cooling

022KA±01
02±18
± PREPARATIONCOOLING
AVENSIS REPAIR MANUAL (RM1018E)
COOLING
PREPARATION
SST
09023±12700Union Nut Wrench 17mmWATER PUMP ASSY(1CD±FTV)
09213±54015Crankshaft Pulley Holding ToolWATER PUMP ASSY(1CD±FTV)
(90105±08076)BoltWATER PUMP ASSY(1CD±FTV)
09249±63010Torque Wrench AdaptorWATER PUMP ASSY(1AZ±FE)
THERMOSTAT(1AZ±FE)
WATER PUMP ASSY(1AZ±FSE)
THERMOSTAT(1AZ±FSE)
09330±00021Companion Flange Holding ToolWATER PUMP ASSY(1CD±FTV)
09950±50013Puller C SetWATER PUMP ASSY(1CD±FTV)
(09951±05010)Hanger 150WATER PUMP ASSY(1CD±FTV)
(09952±05010)Slide ArmWATER PUMP ASSY(1CD±FTV)
(09953±05020)Center Bolt 150WATER PUMP ASSY(1CD±FTV)
(09954±05021)Claw No.2WATER PUMP ASSY(1CD±FTV)
(09954±05031)Claw No.3WATER PUMP ASSY(1CD±FTV)
09960±10010Variable Pin Wrench SetWATER PUMP ASSY(1AZ±FE)
WATER PUMP ASSY(1AZ±FSE)
WATER PUMP ASSY(1CD±FTV)

± PREPARATIONCOOLING
02±19
AVENSIS REPAIR MANUAL (RM1018E)
(09962±01000)Variable Pin Wrench Arm AssyWATER PUMP ASSY(1AZ±FE)
WATER PUMP ASSY(1AZ±FSE)
WATER PUMP ASSY(1CD±FTV)
(09963±00700)Pin 7WATER PUMP ASSY(1AZ±FE)
WATER PUMP ASSY(1AZ±FSE)
(09963±01000)Pin 10WATER PUMP ASSY(1CD±FTV)
Recomended Tools
09216±00021Belt Tension GaugeWATER PUMP ASSY(1CD±FTV)
Equipment
Hexagon wrench (8mm)
Ohmmeter
Radiator cap tester
Thermometer
Torque wrench
Slide calipers
Wooden block
Heater
SSM
08826±00080Seal Packing Black or equivalent
(FIPG)WATER PUMP ASSY(1AZ±FE)
WATER PUMP ASSY(1AZ±FSE)
WATER PUMP ASSY(1CD±FTV)
Coolant
ItemCapacityClassification
Engine coolant (3ZZ±FE)
Left±hand drive vehicles
Right±hand drive vehicles
5.8 liters (6.1 US qts, 5.1 lmp. qts)
5.9 liters (6.2 US qts, 5.2 lmp. qts)
TOYOTA long life coolant
Engine coolant (1ZZ±FE)
Left±hand drive vehicles M/T
A/T
Right±hand drive vehicles M/T
A/T
5.8 liters (6.1 US qts, 5.1 lmp. qts)
5.7 liters (6.0 US qts, 5.0 lmp. qts)
5.9 liters (6.2 US qts, 5.2 lmp. qts)
5.8 liters (6.1 US qts, 5.1 lmp. qts)
TOYOTA long life coolant
Engine coolant (1AZ±FE/1AZ±FSE)
Left±hand drive vehicles M/T
A/T
Right±hand drive vehicles M/T
A/T
6.0 liters (6.3 US qts, 5.3 lmp. qts)
6.3 liters (6.7 US qts, 5.5 lmp. qts)
6.1 liters (6.4 US qts, 5.4 lmp. qts)
6.4 liters (6.8 US qts, 5.6 lmp. qts)
TOYOTA long life coolant
Engine coolant (1CD±FTV)
w/ power heater
w/o power heater
7.6 liters (8.0 US qts, 6.7 lmp. qts)
7.4 liters (7.8 US qts, 6.5 lmp. qts)
TOYOTA long life coolant

031H4±01
03±26
± SERVICE SPECIFICATIONSCOOLING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Radiator drain plug131309
Water pump x Cylinder block Bolt A
Bolt B9.0
1192
11 38.0 in.lbf
8
Water inlet x Cylinder block sub±assy1111 28
Radiator x Radiator support upper1919414
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Water pump x Cylinder block9.09280 in.
lbf
Water pump x Water pump pulley2626519
Water inlet x Cylinder block9.09280 in.
lbf
Radiator support upper x body1919414
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Water pump x Cylinder block9.09280 in.
lbf
Water pump x Water pump pulley2626519
Water inlet x Cylinder block9.09280 in.
lbf
Radiator support upper x body1919414
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Drain plug1313310
Water pump x Cylinder block3132023
Fuel inlet pipe sub±assy x Common rail assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe sub±assy x Injection pump
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Timing belt idler Sub±assy No.1 x Cylinder block3535726
Water inlet x Cylinder block8.89078 in.
lbf
Radiator reserve tank assy x Radiator assy6.06153 in.
lbf
Fan assy w/ motor x Fan shroud assy7.57666 in.
lbf
Upper support x Body1919414
Relay box x Radiator assy5.35447 in.
lbf
Front wheel1031,05076

031H3±01
03±24
± SERVICE SPECIFICATIONSCOOLING
AVENSIS REPAIR MANUAL (RM1018E)
COOLING
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Thermostat
Valve opening temperature
Valve lift at 95
C (203
F)
86 to 90
C (187 to 198
F)
10 mm (0.394 in.) or more
Radiator cap sub±assy
Standard opening pressure
Minimum opening pressure
74 to 103 kPa (0.75 to 1.05 kgf/cm2, 10.7 to 14.9 psi)
59 kPa (0.6 kgf/cm2, 8.6 psi)
Cooling fan
Standard amperage at 20
C (68
F)
8 to 12 A
Cooling fan relay
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Cooling fan relay No.2
Specified condition Between terminals 1 and 2
Between terminals 3 and 4
Between terminals 3 and 5
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
1AZ±FE:
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
Minimum opening pressure
93 ± 122 kPa (0.95 ± 1.25 kgf/cm2, 13.4 ± 17.6 psi)
78 kPa (0.8 kgf/cm2, 11.2 psi)
Cooling fan
Standard amperage at 20
C (68
F)
Standard amperage (No.2 (With Air Conditioner)) at 20
C (68
F)
5.2 to 8.2 A (M/T) 8.3 to 11.3 (A/T)
5.2 to 8.2 A (M/T) 8.3 to 11.3 (A/T)
Cooling fan relay
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Cooling fan relay No.2
Specified condition Between terminals 1 and 2
Between terminals 3 and 4
Between terminals 3 and 5
Cooling fan relay No.3
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
1AZ±FSE:
Thermostat
Valve opening temperature
Valve lift at 95
C (203
F)
86 to 90
C (187 to 198
F)
10 mm (0.394 in.) or more
Radiator cap sub±assy
Standard opening pressure
Minimum opening pressure
74 to 103 kPa (0.75 to 1.05 kgf/cm2, 10.7 to 14.9 psi)
59 kPa (0.6 kgf/cm2, 8.5 psi)

± SERVICE SPECIFICATIONSCOOLING
03±25
AVENSIS REPAIR MANUAL (RM1018E) Cooling fan
Standard amperage at 20
C (68
F)
Standard amperage (No.2 (With Air Conditioner)) at 20
C (68
F)
5.2 to 8.2 A (M/T) 8.3 to 11.3 (A/T)
5.2 to 8.2 A (M/T) 8.3 to 11.3 (A/T)
Cooling fan relay
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Cooling fan relay No.2
Specified condition Between terminals 1 and 2
Between terminals 3 and 4
Between terminals 3 and 5
Cooling fan relay No.3
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
1CD±FTV:
Thermostat
Valve opening temperature
Valve lift at 95
C (203
F)
80 ± 84
C (176 ± 183
F)
8.5 mm (0.33 in.) or more
Radiator cap sub±assy
Standard opening pressure
Minimum opening pressure
93 ± 122 kPa (0.95 ± 1.25 kgf/cm2, 13.4 ± 17.6 psi)
78 kPa (0.8 kgf/cm2, 11.4 psi)
Cooling fan
Standard amperage at 20
C (68
F)
13.2 A
Cooling fan relay
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Cooling fan relay No.2
Specified condition Between terminals 1 and 2
Between terminals 3 and 4
Between terminals 3 and 5
Cooling fan relay No.3
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)

031FR±02
03±12
± SERVICE SPECIFICATIONSINTAKE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Turbo water pipe sub±assy No.1 x Turbocharger sub±assy131359.7
Turbocharger sub±assy x Exhaust manifold5354039
Turbo oil outlet pipe x Turbocharger sub±assy131359.7
Manifold converter sub±assy x Turbocharger sub±assy 1st
2nd8.0
2582
25571 in.
lbf
18
Manifold stay x Manifold converter sub±assy 1st
2nd8.0
6182
62271 in.
lbf
45
Manifold stay x Cylinder block sub±assy 1st
2nd8.0
6182
62271 in.
lbf
45
Turbohcharger stay x Turbocharger sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Turbocharger stay x Cylinder head sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Manifold stay No. 2 x Manifold converter sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Manifold stay No. 2 x Cylinder head sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Exhaust manifold heat insulator No. 2 x Turbocharger sub±assy121228.9
Turbo insulator No. 1 x Manifold converter sub±assy2020415
Turbo insulator No. 1 x Turbocharger sub±assy2020415
Turbo insulator No. 2 x Manifold converter sub±assy2020415
Exhaust pipe assy x Heater bracket sub±assy w/ Cold area7.57666 in.
lbf
Exhaust pipe assy x Body w/ Cold area7.57666 in.
lbf
Heater bracket x Body w/ Cold area7.57666 in.
lbf
Heater pump assy x Heater bracket w/ Cold area7.57666 in.
lbf
Air tube No. 1 x Air tube No. 22525518
Air tube No. 1 x Intake air connector2525518
Air tube No. 1 x Cylinder head cover2525518
Air tube No. 1 x Engine mounting bracket FR2525518
Air cleaner case x Body7.07162 in.
lbf
Intercooler assy x Body7.07162 in.
lbf
Intercooler cooling air duct x Intercooler assy5.05144 in.
lbf
Air cleaner case x Engine mounting insulator LH7.07162 in.
lbf
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Vacuum reservoir sub±assy x Cowl top panel outer8.38573 in.
lbf

05±310
±
DIAGNOSTICS SFI SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E) 


\f  
*
1
CHK ENG
 
 \b
P0110
(05±347)Intake Air Temperature Circuit

Open or short in intake air temperature sensor circuit

Intake air temperature sensor (built in mass air flow meter)

ECM

P0112
(05±347)Intake Air Temperature Circuit
Low Input
Short in intake air temperature sensor circuit

Intake air temperature sensor (built in mass air flow meter)

ECM

P0113
(05±347)Intake Air Temperature Circuit
High Input
Open in intake air temperature sensor circuit

Intake air temperature sensor (built in mass air flow meter)

ECM

P0115
(05±351)Engine Coolant Temperature Cir-
cuit
Open or short in engine coolant temperature sensor circuit

Engine coolant temperature sensor

ECM

P0116
(05±355)Engine Coolant Temperature Cir-
cuit Range/Performance Prob-
lem
Cooling system

Engine coolant temperature sensor

Thermostat

P0117
(05±351)Engine Coolant Temperature Cir-
cuit Low Input
Short in engine coolant temperature sensor circuit

Engine coolant temperature sensor

ECM

P0118
(05±351)Engine Coolant Temperature Cir-
cuit High Input
Open in engine coolant temperature sensor circuit

Engine coolant temperature sensor

ECM

P0120
(05±356)Throttle/Pedal Position Sensor/
Switch ºAº Circuit
Throttle position sensor (built in throttle body)

ECM
P0121
(05±362)Throttle/Pedal Position Sensor/
Switch ºAº Circuit Range/Perfor-
mance Problem

Throttle position sensor (built in throttle body)
P0122
(05±356)Throttle/Pedal Position Sensor/
Switch ºAº Circuit Low Input

Throttle position sensor (built in throttle body)

VTA1 circuit short

VC circuit open

ECM

P0123
(05±356)Throttle/Pedal Position Sensor/
Switch ºAº Circuit High Input

Throttle position sensor (built in throttle body)

VTA1 circuit open

E2 circuit open

VC and VTA1 circuit are short±circuited

ECM

P0130 *3
(05±363)
Oxygen Sensor Circuit (Bank 1
Sensor 1)

Open or short in heated oxygen sensor circuit

Heated oxygen sensor

Heated oxygen sensor heater

EFI relay

Air induction system

Fuel pressure

Injector

ECM

P0133 *3
(05±374)
Oxygen Sensor Circuit Slow Re-
sponse (Bank 1 Sensor 1)

Open or short in heated oxygen sensor circuit

Heated oxygen sensor

Heated oxygen sensor heater

EFI relay

Air induction system

Fuel pressure

Injector

ECM


±
DIAGNOSTICS SFI SYSTEM(1AZ±FSE)
05±355
AVENSIS REPAIR MANUAL (RM1018E)
DTCP0116ENGINE COOLANT TEMP. CIRCUIT
RANGE/PERFORMANCE PROBLEM
CIRCUIT DESCRIPTION
Refer to DTC P0115 on page 05±351.
DTC No.DTC Detection ConditionTrouble Area
P0116
When THW is greater than ±40
C (±40
F) but less than 60
C
(140
F), and THA is greater than ±6.7
C (20
F), and when
starting engine, conditions (a) and (b) continue (2 trip detection
logic):
(a)Vehicle speed is changing (Not stable)
(b)THW change is lower than 3
C (5.4
F) from THW since
when starting engine

Cooling system

Engine coolant temperature sensor

Thermostat
INSPECTION PROCEDURE
HINT:

If different DTCs related to different systems that have terminal E2 as the ground terminal are output
simultaneously, terminal E2 may be open.

Read freeze frame data using the hand±held tester. Freeze frame data records the engine conditions
when a malfunction is detected. When troubleshooting, it is useful for deter\
mining whether the vehicle
was running or stopped, the engine was warmed up or not, the air±fuel ra\
tio was lean or rich, etc. at
the time of the malfunction.
1READ OUTPUT DTC(IN ADDITION TO P0116)
(a)Read the DTC using the hand±held tester.
Result:
DisplayProceed to
Only ºP0116º is output.A
ºP0116º and other DTCs are output.B
HINT:
If any other codes besides ºP0116º are output, perform the troubleshooting for those DTCs first.
BGO TO RELEVANT DTC CHART (See page 05±309)
A
2INSPECT THERMOSTAT (See page 16±27)
NGREPLACE THERMOSTAT (See page 16±35)
OK
REPLACE ENGINE COOLANT TEMPERATURE SENSOR
05CK2±01