TOYOTA AVENSIS 2005 Service Repair Manual

A75342
Battery4
5
± FUELFUEL 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.

110UW±01
A75341
Fuel
Pump
Connector
B00679
Vinyl or Plastic Bag
±
FUEL FUEL 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.

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
± FUELFUEL 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, be
careful 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

SST
Retainer
(at 4 places)
Insert
A50705
A60083
Fuel Pipe
Clamp No.1
A
A
B12941
B12944
A82344
Vinyl Bag or plastic Bag
± FUELFUEL 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.

B16534Push
B16535Pull
11±18
±
FUEL FUEL 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)

110TZ±01
A78471
Retainer
(at 4 places)
Insert
SST
Turn
Fuel Pipe
Clamp
A76220
O±ring
Nylon Tube HousingPipe
Retainer
A78472
±
FUEL FUEL INJECTOR ASSY(1ZZ±FE/3ZZ±FE)
11±11
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±1)
2.REMOVE CYLINDER HEAD COVER NO.2 (See page 10±9)
3. SEPARATE FUEL TUBE SUB±ASSY
(a) Remove the fuel pipe clamp.
(b) Using SST, disconnect the fuel tube.SST 09268±21010
(1) Assemble SST to the connection of the fuel tube asshown in the illustration.
(2) Turn SST, align the retainers inside the connector
with SST into the connector.
(3) Push in the SST and the connector together to- wards the fuel tube assembly.
NOTICE:

Check if there is any dirt or mud on the pipe and
around the connector before disconnecting them and
remove the dirt as necessary.

Do not bent and twist the nylon tube.

When the connector and pipe are stuck, push and pull
the connector to free. Pull the connector out carefully.

Prevent the disconnected pipe and connector from
being damaged and foreign objects from being
introduced, cover with a vinyl or plastic bag.
4. REMOVE FUEL DELIVERY PIPE SUB±ASSY
(a) Disconnect the ventilation hose.

A78473
(a)(a)
(a)
(a)
(b)
(b)
(b)
A78480
A78475
Delivery Pipe No. 1 spacer
Insulator
A78476
11±12
± FUELFUEL INJECTOR ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Disconnect the 4 fuel injector connectors.
(c) Remove the 3 wire harness clamps.
(d) Remove the 3 bolts, and then remove the fuel delivery
pipe together with the 4 fuel injectors.
NOTICE:
Be careful not to drop the fuel injectors when removing the
fuel delivery pipe.
(e) Remove the 2 delivery pipe No. 1 spacers and the 4 insu-
lators from the cylinder head.
5. REMOVE FUEL INJECTOR ASSY
(a) Pull out the 4 fuel injectors from the fuel delivery pipe.

A78477
New O±ring
1ZZ±FE:
A78478
New O±ring
3ZZ±FE:
New Grommet
A78479
Turn
Push
A78474
Turn
A
A
B
± FUELFUEL INJECTOR ASSY (1ZZ±FE/3ZZ±FE)
11±13
AVENSIS REPAIR MANUAL (RM1018E)
6. INSTALL FUEL INJECTOR ASSY
(a) Install new grommets to each fuel injector. (3ZZ±FE)
(b) Apply a light coat of spindle oil or gasoline to new O±rings,
and install them to each fuel injector.
(c) Apply a light coat of spindle oil or gasoline on the place
where the fuel delivery pipe contacts the O±ring.
(d) Push the fuel injector while twisting it back and forth to
install it to the fuel delivery pipe.
NOTICE:

Be careful not to twist the O±ring.

After installing the fuel injectors, check that they turn
smoothly. If not, reinstall it with a new O±ring.
7. INSTALL FUEL DELIVERY PIPE SUB±ASSY
(a) Instal 4 new insulators and the 2 delivery pipe No. 1
spacers to the cylinder head.
(b) Place the fuel delivery pipe and 4 fuel injectors together
to the cylinder head.
NOTICE:
Be careful not to drop the fuel injectors when installing the
fuel delivery pipe.
(c) Temporarily install 3 bolts which are used to secure the
fuel delivery pipe to the cylinder head.
(d) Check that the fuel injectors rotate smoothly.
If fuel injectors do not rotate smoothly, the probable cause is in-
correct installation of O±ring. Replace with the O±ring.
(e) Tighten the 3 bolts.
Torque:
19 N
m (194 kgf
cm, 14 ft
lbf) for bolt A
9.0 N
m (92 kgf
cm, 80 in.
lbf) for bolt B
(f) Install the 3 wire harness clamps.
(g) Connect the 4 fuel injector connectors.
(h) Connect the ventilation hose.

A81613
Fuel Pipe
Clamp
Push
11±14
±
FUEL FUEL INJECTOR ASSY(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
8.CONNECT FUEL TUBE SUB±ASSY
(a)Push in the 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 connector and the pipe
are securely connected by pulling on them.
(b)Install the fuel pipe clamp.
9.CHECK FOR FUEL LEAKS (See page 11±5)
10.INSTALL CYLINDER HEAD COVER NO.2 (See page 10±9)

110TY±01
A78470

Fuel Injector O±Ring

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
7.0 (71, 62 in.´lbf)
Ventilation Hose
Fuel Injector Connector No. 1 Spacer
Injector Vibration
InsulatorFuel Delivery Pipe
Sub±assy
Fuel Tube Sub±assy Fuel Pipe Clamp No. 2 Cylinder Head Cover No. 2
Fuel Injector O±Ring

Fuel Injector Grommet
Fuel Injector Assy Fuel Injector Assy 1ZZ±FE:
Clip 3ZZ±FE:
19 (189, 14)
9.0 (91, 80 in.´lbf)
11±10
± FUELFUEL INJECTOR ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
FUEL INJECTOR ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS