TOYOTA AVENSIS 2003 Service Repair Manual

A81614
Push
A81615
Push
A81616
Tube Joint Clip
Collar
2
1
11±88
±
FUELFUEL PUMP ASSY(GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
9.CONNECT FUEL EVAPORATION TUBE SUB±ASSY NO.2
(a)Push in the fuel tube connector to the pipe until it makes
ºclickº sound.
NOTICE:

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

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

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

After connecting, check if the fuel tube connector and
the pipe are securely connected by pulling on them.
11.C ONNECT FUEL TANK RETURN TUBE (1AZ±F SE
ENGINE TYPE)
(a)Install in the fuel return tube with the tube joint clip.
NOTICE:

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

Check that the fuel tube joint is inserted securely.

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

After installing the tube joint clip, check that the fuel
tube joint has not been pulled off.
12.CHECK FOR FUEL LEAKS
HINT:

1ZZ±FE/3ZZ±FE: 11±5

1AZ±FE: 11±19

1AZ±FSE: 11±33
13.INSTALL REAR FLOOR SERVICE HOLE COVER
14.INSTALL REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 72±32)
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110UY±01
Fuel Tube Connector
A50710
Fuel Tube Connector
SST
(Hose)
B12947
SST (Hose)SST
(Clamp)
Vinyl Tube SST (Union)
O±Ring
A51875
11±22
±
FUELFUEL SYSTEM(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1.INSPECT FUEL INJECTOR ASSY
(a)Inspect injector resistance (1)Using an ohmmeter, measure the resistance be-tween the terminals.
Resistance: 13.4 to 14.2at 20
C (68
F)
If the resistance is not as specified, replace the injector.
(b)Inspect injector inspection
CAUTION:
This test involves high±pressure fuel and electricity. Take
every precaution regarding safe handling of both the fuel
and the electricity. Preform this test in a safe area, and
avoid any sparks or flame. Do not smoke.
(1)Obtain new No. 1 fuel pipe (part No. 23901±0H040)and remove the fuel tube connector from the pipe.
(2)Install the fuel tube connector to SST (hose), then connect the tube connector and the fuel pipe.
SST09268±41047 (95336±08070)
CAUTION:
Connect the fuel tube connector (quick type) after observ-
ing the precautions to prevent fuel from spraying.
(3)Install the O±ring to the injector.
(4)Connect SST (union and hose) to the injector, andhold the injector and the union with SST (clamp)
SST09268±41047 (09268±41110, 09268±41300, 95336±08070)
(5)Put the injector into a graduated cylinder.
CAUTION:
Install a suitable vinyl tube onto the injector to contain gas-
oline spray. (6)Operate the fuel pump.(See Page 11±19)
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SST
A50700
B00069
A16628A32859
±
FUEL FUEL SYSTEM (1AZ±FE)
11±23
AVENSIS REPAIR MANUAL (RM1018E)
(7) Connect SST (wire) to the injector and the battery
for 15 seconds, and measure the injection volume
with a graduated cylinder. Test each injector 2 or 3
times.
SST 09842±30080
Injection volume:
Injection volumeDifference between each injector
60 to 73 cm3 (3.6 to 4.5 cu in.)
in 15 seconds13 cm3 (0.9 cu in.) or less
NOTICE:
Always do the switching at the battery side.
If the injection volume is not as specified, replace the injector.
(c) Inspect leakage (1) In the condition above, disconnect the test probesof SST (wire) from the battery and check the fuel
leakage from the injector.
Fuel drop: 1 drop or less in 12 minutes
2. INSPECT FUEL PUMP
(a) Insect fuel pump resistance. (1) Using an ohmmeter, measure the resistance be-tween the terminals.
Resistance: 0.2 to 3.0
at 20 C (68 F)
(b) Inspect fuel pump operation (1) Apply battery voltage to both the terminals. Checkthat the pump operates.
NOTICE:

These tests must be done quickly (within 10 seconds)
to prevent damage to the pump.

Keep fuel pump as far away from the battery as pos-
sible.

Always do the switching at the battery side.
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110UX±01
Fuel Tube Connector
A50710
A60083
Fuel Pipe
Clamp No.1
AA
B12941
±
FUELFUEL SYSTEM(1AZ±FE)
11±19
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1.CHECK FUEL PRESSURE
(a)Discharge the pressure in the fuel system and take pre-
cautions for possible fuel spillage.(See page 11±15)
(b) Check that the battery voltage is above 12 V.
(c) Disconnect the negative (±) battery cable.
(d) Pull out the connecter from a new fuel tube.
HINT:
Part No. 23901±0H040
(e) Remove the fuel pipe clamp No.1 from the fuel tube con- nector.
(f) Disconnect the fuel tube connector from the fuel pipe while pinching part A with fingers as shown in the illustra-
tion.
CAUTION:

Do not disconnect the fuel tube connector (quick
type) until after you have discharged the fuel system
pressure and taken appropriate steps to prevent fuel
spillage.

There may be remained pressure in the fuel lines after
discharging the pressure.
Take precautions to prevent fuel from spraying on
you or your clothing or inside the engine compart-
ment.
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No.1 Fuel Pipe
Fuel Tube Connector
SST
(Clip)
SST (T joint)SST
SST
(Hose)
B12975
11±20
±
FUEL FUEL SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(g) Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration.
SST 09268±41047(95336±08070),09268±45014 (09268±41250, 09268±41200, 09268±41220)
(h) Wipe up any gasoline.
(i) Reconnect the negative (±) battery cable.
(j) Connect the hand±hand tester to the DLC3.
(k) Measure the fuel pressure. Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check the fuel hoses connections, the fuel
pump, the fuel filter and the fuel pressure regulator.
(l) Disconnect the hand±held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle. Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure:147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, the pres-
sure regulator and/or the injectors.
(q) After checking the fuel pressure, disconnect the negative (±) battery cable and carefully remove SST and the fuel
tube connector to prevent gasoline from splashing.
(r) Reconnect the No. 1 fuel pipe (fuel tube connector).
CAUTION:
After taking the precautions, connect the fuel tube con-
necter (quick type).
2. CHECK FUEL PUMP OPERATION AND FUEL LEAK
(a) When using the hand±held tester (1) Connect the hand±held tester to the DLC3.
(2) Turn the ignition switch ON and the hand±held tes-
ter main switch ON.
NOTICE:
Do not start the engine. (3) Select the active test mode on the hand±held tester.
(4) Perform the active test. Check that the fuel pumpoperates and check for fuel leaks.
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A75342
Battery4
5
±
FUEL FUEL SYSTEM (1AZ±FE)
11±21
AVENSIS REPAIR MANUAL (RM1018E)
(b) When not using hand±held tester
(1) Connect the positive (+) lead form the battery to ter-minal 4 of the connector and connect the negative
(±) lead to terminal 5.
(2) Check that the pump operates.
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110UW±01
A75341
Fuel
Pump
Connector
B00679
Vinyl or Plastic Bag
±
FUELFUEL SYSTEM(1AZ±FE)
11±15
AVENSIS REPAIR MANUAL (RM1018E)
FUEL SYSTEM(1AZ±FE)
PRECAUTION
1.PRECAUTION
(a)Before working on fuel system, disconnect negative (±) battery cable.
(b)Do not smoke or work near fire when handling the fuel system.
(c)Keep gasoline away from rubber or leather parts.
2.DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:

Do not disconnect any part of the fuel system until
you have discharged the fuel system pressure.

Even after discharging the fuel pressure, place a
shop rag over fittings as you separate them to reduce
risk of fuel spray on yourself or in the engine compart-
ment.
(a)Disconnect the fuel pump connector.
(b)Start the engine. After the engine has stopped, turn the ignition switch OFF.
(c)Disconnect the negative (±) battery cable.
(d)Connect the fuel pump connector.
3.FUEL SYSTEM
(a)When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these proce-
dures.
(1)Discharge the pressure in the fuel system. (See step 2)
(2)Disconnect the fuel pump tube. (See page 11±93)
(3) Drain the fuel that remained inside the fuel pump
tube.
(4) Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt.
(5) Place a tray under the vehicle or point of disconnec- tion to catch any fuel that may spill.
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WRONG
CORRECT
Delivery Pipe
New O±ring
Injector
A51878
Delivery Pipe O±ring
Grommet
B09613
O±ring Retainer Pipe
Nylon Tube Housing
A50709
A75343
Fuel Pipe Clamp No.2
A60818
SST
11±16
±
FUEL FUEL SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Observe the following precautions when removing and installing fuel injectors.
NOTICE:
Never reuse the O±ring.
(1) When installing a new O±ring to the injector, becareful not to damage the injector.
(2) Coat the new O±ring with grease or gasoline before
installing. Never use engine oil, gear oil or brake oil.
(c) Install the injector to the delivery pipe and cylinder head as shown in the illustration. Before installing the injector,
be sure to apply grease or gasoline on the place where
the delivery pipe contacts the O±ring of the injector.
(d) Observe these precautions when disconnecting the fuel delivery pipe.
HINT:
The structure of the metallic connector is as shown in the il-
lustration on the left.
(1) Remove the fuel pipe clamp No.2.
(2) Find the metallic connector of the fuel tube assem-bly, slide it towards the vehicle rear and hold it as
it is.
(3) Assemble SST to the connection of the fuel pipe as shown the illustration.
SST 09268±21010
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SST
Retainer
(at 4 places) Insert
A50705
A60083
Fuel Pipe
Clamp No.1
A
A
B12941
B12944
A82344
Vinyl Bag or plastic Bag
±
FUEL FUEL SYSTEM (1AZ±FE)
11±17
AVENSIS REPAIR MANUAL (RM1018E)
(4) Turn SST, align the retainers inside the connector
with SST chamfered parts and insert SST into the
connector.
(5) Slide SST and the connector together towards the fuel tube assembly.
(e) Observe these following precautions when disconnecting the fuel tube connector (quick type).
(1) Remove the fuel pipe clamp No.1.
(2) Check that there is no dirt or mud on the pipe and
around the connector before disconnecting them.
Clean them if necessary.
(3) Disconnect the connector from the hose while pinching part A with fingers as shown in the illustra-
tion.
(4) When the connector and the pipe are stuck, push and pull the connector to release and pull the con-
nector out from the pipe carefully.
(5) Inspect that there is no dirt or mud on the sealing
surface of the disconnected pipe. Clean it away if
necessary.
(6) To prevent the disconnected pipe and connector from being damaged and foreign objects from being
introduced, cover them with a vinyl or plastic bag.
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B16534Push
B16535Pull
11±18
±
FUELFUEL SYSTEM(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(f)Observe these precautions when connecting the fuel tube connectors (Quick Type):
(1)Check that there is no damage or foreign objects inthe connected part of the pipe.
(2)Match the axis of the connector with the axis of the pipe, and push into the connector until the connec-
tor makes a ºclickº sound. If the connection is tight,
apply little amount of fresh engine oil on the tip of the
pipe.
(3)After having finished the connection, check if the pipe and the connector are securely connected by
pulling on them.
(4)Check for fuel leaks.
4.CHECK FOR FUEL LEAKS
(a)Check that there are no fuel leaks after doing maintenance anywhere on t\
he fuel system. (See page 11±19)
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