TOYOTA AVENSIS 2002 Repair Manual

A81588
3
1 22
A63387
Retainer Fuel Tube Connector
O±ring
Pipe
A77890
A77894
A78270
± FUELFUEL TANK ASSY (DIESEL)
11±107
AVENSIS REPAIR MANUAL (RM1018E)
16. DISCONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a) Pinch the tab of the retainer to remove the lock claws and
pull down it as shown in the illustration.
(b) Pull out the fuel tank main tube.
NOTICE:

Check if there is any dirt or mud around the connector
before this operation and remove the dirt as neces-
sary.

Be careful of mud because the quick connector has
an O±ring which seals the pipe and the connector that
can be contaminated.

Do not use any tool in this operation.

Do not bend or twist the nylon tube. Protect the con-
nector by covering it with a vinyl or a plastic bag.

When the pipe and connector are stuck, push and pull
the connector to release. Pull out the connector from
the pipe carefully.
17. REMOVE FUEL TANK ASSY
(a) Set up a transmission jack under the fuel tank.
(b) Remove the 4 bolts and 2 fuel tank bands, and then re-
move the fuel tank.
18. REMOVE FUEL TANK MAIN TUBE SUB±ASSY
(a) Unfasten the 5 claws, and remove the fuel tank return
tube from the fuel tank.
19. REMOVE FUEL EVAPORATION TUBE SUB±ASSY
NO.2
(a) Unfasten the claw, and remove the fuel evaporation tube
from the fuel tank.

A77892
A77893
UpperFuel Tank
Rear
Hose Clamp
A81618
11±108
±
FUEL FUEL TANK ASSY(DIESEL)
AVENSIS REPAIR MANUAL (RM1018E)
20.REMOVE FUEL TANK MAIN TUBE SUB±ASSY
(a)Unfasten the 4 claws, and remove the fuel tank main tube from the fuel tank.
21.INSTALL FUEL TANK MAIN TUBE SUB±ASSY
22.INSTALL FUEL EVAPOR ATION TUBE SUB±ASSY
NO.2
(a)Install the hose clamp as shown in the illustration.
23.INSTALL FUEL TANK RETURN TUBE
24.INSTALL FUEL TANK ASSY Torque: 40 N
m (400 kgf
cm, 29 ft
lbf)
25.CONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a)Push in the fuel tube connector to the pipe, and push up retainer to lock the claws.
NOTICE:

Check if there is any damage or foreign objects on the connected part.

After connecting, check if the quick connector and the pipe are securely\
connected by pulling
on them.
26.CONNECT FUEL TANK RETURN TUBE
27.CONNECT FUEL TANK TO FILLER PIPE HOSE
28.CONNECT BREATHER TUBE FUEL HOSE
29.INSTALL PARKING BRAKE CABLE ASSY NO.3 Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
30.INSTALL PARKING BRAKE CABLE ASSY NO.2 Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
31.INSTALL FUEL TANK PROTECTOR NO.1
Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
32.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±10)
33. ADD FUEL

A63379
Mark
A62989
SST
A63380
Area
Arrow
Mark
A64697
A64698
± FUELFUEL TANK ASSY (DIESEL)
11±109
AVENSIS REPAIR MANUAL (RM1018E)
34. INSTALL FUEL AND EVAPORATION VENT TUBE
SUB±ASSY
(a) Align the arrow marks of the fuel pump bracket and the
fuel tank.
(b) Temporarily install the retainer.
(c) Mount SST to the retainer.
SST 09808±14010
(d) Tighten the retainer until the arrow mark located on the re-
tainer is positioned within the area shown in the illustra-
tion.
(e) Check that the arrow marks of the fuel pump bracket and
fuel tank are aligned.
35. CONNECT FUEL EVAPORATION TUBE SUB±ASSY
NO.2
(a) Push in the quick connector to the pipe until connector
makes ºclickº sound.
NOTICE:

Check if there is any damage or foreign objects on the
connected part of the pipe.

After connecting, check if the pipe and the connector
are securely connected by pulling on them.
36. CONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a) Push in the quick connector to the pipe until connector
makes ºclickº sound.
NOTICE:

Check if there is any damage or foreign objects on the
connected part of the pipe.

After connecting, check if the pipe and the connector
are securely connected by pulling on them.

A64699
11±110
±
FUEL FUEL TANK ASSY(DIESEL)
AVENSIS REPAIR MANUAL (RM1018E)
37.CONNECT FUEL TANK RETURN TUBE
(a)Connect the fuel tank return tube with the tube joint clip.
NOTICE:

Check that there is no scratch or foreign objects on
the connecting parts.

Check that the connector is inserted securely.

Check that the clip of the tube joint is on the collar of
the connector.

After installing the tube joint clip, check that the con-
nector is not pulled off.
38.CHECK FOR FUEL LEAKS (See page 11±60)
39. CHECK FOR EXHAUST GAS LEAKS
40.INSTALL FLOOR PANEL BRACE FRONT (See page 15±10)
41. INSTALL REAR FLOOR SERVICE HOLE COVER
42.INSTALL REAR SEAT CUSHION ASSY (See page 72±27)

110U6±01
A78441
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torqueSeat Fixed Type:
Rear Seat Cushion Assembly
Rear Floor Service Hole Cover
Fuel Pump Connector
Fuel Evaporation Tube
Sub±assy No. 2 Fuel Tank Main Tube
Sub±assy
Tube Joint Clip
Fuel Pump Gauge Retainer
Fuel Suction
w/ Pump & Gage Tube Assy

Fuel Suction Tube
Set Gasket x4
1AZ±FSE:
Fuel Tank Return Tube
± FUELFUEL TANK ASSY (GASOLINE)
11±89
AVENSIS REPAIR MANUAL (RM1018E)
FUEL TANK ASSY (GASOLINE)
COMPONENTS

A78517
N´m (kgf´cm, ft´lbf) : Specified torque

Non±reusable partRHD:
Front Floor Footrest 1ZZ±FE/3ZZ±FE:
Floor Carpet Assy FrontClip
Compression Spring
Exhaust Pipe
Gasket
Exhaust Pipe Assy Front
Floor Panel Brace Front
43 (440, 33)
30 (302, 22)

Exhaust Pipe
Gasket
Compression Spring
43 (440, 32)
Exhaust Pipe Assy Center
43 (440, 32)

Exhaust Pipe
Gasket
Floor Panel Brace Front
30 (302, 22)
Compression Spring
43 (440, 32)

Exhaust Pipe
Gasket
1AZ±FE:
Exhaust Pipe Assy Center
43 (440, 32)

Exhaust Pipe
Gasket
Floor Panel Brace Front
30 (302, 22)
Compression Spring
43 (440, 32)

Exhaust Pipe
Gasket
1AZ±FE (Leaded Gasoline)
1AZ±FSE:
w/o HID Sensor: 11±90
± FUELFUEL TANK ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)

A77881
Fuel Tank AssyFuel Hose No. 1Fuel Tank
to Filler Pipe Hose
Fuel Tank Band Sub±assy
No. 1
Fuel Tank Band Sub±assy
No. 1 LH
Fuel Tank Protector
No. 1
Parking Brake Cable Assy
No. 2
Parking Brake Cable Assy
No. 3
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
5.4 (54, 47 in.
lbf)x4
40 (400, 29)
40 (400, 29)
N´m (kgf´cm, ft´lbf) : Specified torque
± FUELFUEL TANK ASSY (GASOLINE)
11±91
AVENSIS REPAIR MANUAL (RM1018E)

A77882
1AZ±FSE:
Fuel Tank Return TubeFuel Evaporation Tube Sub±assy
No. 2
Fuel Tank Main Tube Sub±assy
Fuel Tank Assy
11±92
± FUELFUEL TANK ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)

110U5±01
A78493
A80060
w/o HID Sensor:
w/ HID Sensor:
(c)
(d)
(c)
±
FUEL FUEL TANK ASSY(GASOLINE)
11±93
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.DISCHARGE FUEL SYSTEM PRESSURE
HINT:

1ZZ±FE/3ZZ±FE: 11±1

1AZ±FE: 11±15

1AZ±FSE: 11±30
2.REMOVE REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 72±32)
3.REMOVE COVER, RR FLOOR SERVICE HOLE (See page 11±85)
4.DISCONNECT FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE)
(See page 11±85)
5.DISCONNECT FUEL TANK MAIN TUBE SUB±ASSY (See page 11±85)
6.DISCONNECT FUEL EVAPORATION TUBE SUB±ASSY NO.2 (See page 11±85)
7.REMOVE FUEL SUCTION W/PUMP & GAGE TUBE ASSY (See page 11±85)
SST 09808±14010
8. DRAIN FUEL
9. REMOVE FRONT FLOOR FOOTREST (W/O HID SENSOR)
10.REMOVE FLOOR PANEL BRACE FRONT (See page 15±2)
11. REMOVE EXHAUST PIPE ASSY CENTER(1ZZ±FE/3ZZ±FE ENGINE TYPE)
(a) Using a clip remover, remove the 2 clips. (w/o HID Sensor)
(b) Open the floor carpet. (w/o HID Sensor)
(c) Disconnect the heated oxygen sensor connector.
(d) Remove the grommet. (w/o HID Sensor)

A78518
(e)(e)
(e)
(e)
(f)
(f) 11±94
± FUELFUEL TANK ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
(e) Remove the 4 bolts and 4 compression springs.
(f) Remove the exhaust pipe front from the 2 exhaust pipe
supports.
(g) Remove each gasket from the exhaust manifold and the
exhaust pipe front.