TOYOTA AVENSIS 2005 Service Repair Manual

A79581
A79582
A79583
± FUELFUEL INJECTOR ASSY (1AZ±FSE)
11±43
AVENSIS REPAIR MANUAL (RM1018E)
(e) Using a Torx socket, remove the 2 stud bolts.
(f) Disconnect the 2 vacuum hoses and the vacuum sensor
connector.
(g) Remove the intake air control valve assy and gasket.

A79584
A79585
A79586
A79587
A79588
11±44
± FUELFUEL INJECTOR ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(h) Remove the intake manifold.
12. REMOVE SURGE TANK STAY NO.1
(a) Disconnect the wire harness from the surge tank stay
No.1.
(b) Remove the 3 bolts and the surge tank stay No.1.
13. REMOVE INTAKE MANIFOLD INSULATOR NO.2
(a) Disconnect the fuel injector assy connector and the knock
sensor connector.
(b) Remove the intake manifold insulator No.2 from the cylin-
der block.
14. REMOVE NOZZLE HOLDER CLAMP
(a) Using a Torx socket (T±40), remove the nozzle holder
clamp.
15. REMOVE FUEL DELIVERY PIPE SUB±ASSY
(a) Disconnect the fuel pressure sensor connector.
(b) Disconnect the fuel hose from the fuel delivery pipe sub±
assy.
(c) Remove the 5 bolts.
(d) Remove the fuel injector and the fuel delivery pipe sub±
assy together.

A79589
A79590
A80297
E±ring
Fuel Injector
Back±up Ring No. 3
Fuel Injector
Back±up Ring No. 2
Fuel Injector
Back±up Ring No. 1O±ring
± FUELFUEL INJECTOR ASSY (1AZ±FSE)
11±45
AVENSIS REPAIR MANUAL (RM1018E)
(e) Remove the 4 gaskets and 4 fuel injector seal.
16. REMOVE FUEL INJECTOR ASSY
(a) Remove the fuel injector assy from the fuel delivery pipe
sub±assy.
NOTICE:
Be careful not to damage the sealing surface of the fuel de-
livery pipe when removing the fuel injector.
17. INSTALL FUEL INJECTOR ASSY
(a) Install new fuel injector back±up ring No.1, No.2, No.3, a
new O±ring and a new E±ring to the fuel injector assy in
the following sequence:
(1) Fuel Injector back±up ring No.1
(2) Fuel Injector back±up ring No.2
(3) O±ring
(4) Fuel Injector back±up ring No.3
(5) E±ring
NOTICE:

There is a draft angle inside the back±up ring No.1
and No.2. Put the draft angle downward when instal-
ling those rings to the fuel injector.

The back±up ring No.1 and No.2 have a diagonal slit.
Pay attention to the splice of the slits after installing
them.

After Installation of these 5 rings to the fuel injector,
check that there are no damages and foreign objects
on them.
(b) Apply a little amount of fuel to the O±ring on the fuel injec-
tor and the mounting hole on the fuel delivery pipe.

A79592
5
A79593
A79594
11±46
± FUELFUEL INJECTOR ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Install the fuel injector to the fuel delivery pipe as shown
in the illustration.
NOTICE:

Be careful not to damage the sealing surface of the
fuel delivery pipe when installing the injector.

Check that there are no damages and foreign objects
in the fuel injector mounting hole of the fuel delivery
pipe sub±assy.

In order to avoid damaging, be sure to apply fuel to
both the O±ring and the mounting hole before instal-
ling the fuel injector to the fuel delivery pipe.
18. INSTALL FUEL DELIVERY PIPE SUB±ASSY
(a) Install a new gasket and a new fuel injector seal to the cyl-
inder head.
NOTICE:
Pay attention the mounting orientation of the fuel injector
seal.
(b) Install the fuel delivery pipe sub±assy and the fuel injector
assy together to the cylinder head.
NOTICE:

Remove carbon from the tip of the fuel injector if nec-
essary.

Since the fuel injector tip is sensitive,do not give
physical impact to the tip.

If you mistakenly drop the fuel injector, replace it with
a new one.

Check that there are no damages and foreign objects
on the fuel injector mounting area of the cylinder
head.
(c) Temporarily install the fuel delivery pipe sub±assy with
the 5 bolts.
19. INSTALL NOZZLE HOLDER CLAMP
(a) Align the keyway of the fuel injector with the nozzle holder
clamp and fit them.
(b) Using a Torx socket (T±40), instal the nozzle holder clamp
to the cylinder head.
Torque: 13 N
m (127 kgf
cm, 9 ft
lbf)
(c) Tighten the 5 bolts until they reach the specified torque to
secure the fuel delivery pipe sub±assy.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
(d) Connect the fuel hose to the fuel delivery pipe sub±assy.
(e) Connect the fuel pressure sensor connector.
20. INSTALL INTAKE MANIFOLD INSULATOR NO.2
(a) Install the intake manifold insulator No. 2 to the cylinder block.
(b) Connect the fuel injector assy connector and the knock sensor connector.

A79595
42135
A79579
±
FUEL FUEL INJECTOR ASSY(1AZ±FSE)
11±47
AVENSIS REPAIR MANUAL (RM1018E)
21.INSTALL SURGE TANK STAY NO.1
(a)Install the surge tank stay No. 1 with the 3 bolts.
Torque: 21 N
m (210 kgf
cm, 15 ft
lbf)
(b)Connect the wire harness to the surge tank stay No. 1.
22.INSTALL INTAKE MANIFOLD
(a)Set a new gasket to the intake manifold.
(b)Temporarily install the intake manifold to the engine assy.
(c)Temporarily install the intake air control valve and a newgasket between the intake manifold and cylinder head,
and then check that the stud bolt holes are aligned.
(d)Connect the 2 vacuum hose and the vacuum sensor con-
nector.
(e)Using a Torx socket, install and tighten the 2 stud bolts to secure the intake manifold, the intake air control valve
and gasket.
Torque: 9.5 N
m (97 kgf
cm, 84 in.
lbf)
(f)In order to install the intake manifold to the cylinder head, tighten the 3 bolts and 2 nuts in the sequence shown in
the illustration.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(g)Install the intake manifold to the surge tank stay No.1 with
the 2 bolts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(h)Connect the union to connector tube hose to the brake booster assy.
(i)Connect the 2 vacuum hoses to the VSV.
(j)Install the ventilation hose No. 1.
23.INSTALL FUEL PUMP ASSY (See page 11±52)
24. INSTALL ENGINE COVER BRACKET
(a) Install the engine cover bracket the bolt. Torque: 38 N
m (388 kgf
cm, 28 ft
lbf)
25. INSTALL CHARCOAL CANISTER ASSY

11±48
±
FUEL FUEL INJECTOR ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
26.INSTALL THROTTLE BODY ASSY (See page 10±44)
27.INSTALL AIR CLEANER CAP SUB±ASSY (See page 10±44)
28.ADD ENGINE COOLANT (See page 16±31)
29.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
30. CHECK FOR FUEL LEAKS
31. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
32. INSTALL ENGINE ROOM COVER SIDE
33. INSTALL RADIATOR SUPPORT OPENING COVER

110TC±01
A78507
Mass Air Flow
Meter Connector
N´m (kgf´cm, ft´lbf) : Specified torqueEngine Cover Sub±assy
No. 1
7.0 (71, 62 in.
lbf)
Air Cleaner Cap
Sub±assyVSV
Connector Fuel Vapor Feed Hose
Clip
Engine Room Cover Side
Radiator Support Opening Cover
Clip
Retainer
x2
x4
1.5 (15, 13 in.
lbf)
± FUELFUEL INJECTOR ASSY (1AZ±FSE)
11±37
AVENSIS REPAIR MANUAL (RM1018E)
FUEL INJECTOR ASSY (1AZ±FSE)
COMPONENTS

A78508
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torqueThrottle Body AssyThrottle Motor Connector

Throttle Body Gasket
Water By±pass Hose No. 2
Water By±pass Hose No. 1
9.0 (90, 80 in.
lbf)
x4
x4
21 (210, 15)Throttle Body Bracket
8.4 (86, 74 in.
lbf)
Ground Terminal
Wire Harness Protector
8.4 (86, 74 in.
lbf)
11±38
± FUELFUEL INJECTOR ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)

A79577
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
GasketFuel Tube Sub±assy
Fuel Pipe Clamp
Fuel Pressure Pulsation
Damper Assy Fuel Pump Assy

Fuel Pump
Insulator
Fuel HoseFuel Pipe Sub±assy No. 1

Fuel Injector Back±up Ring No. 1
25 (255, 18)
33 (331, 24)
9.0 (92, 80 in.
lbf)
38 (388, 28 )
30 (306, 22)

Fuel Injector Back±up Ring No. 2

Fuel Injector Back±up Ring No. 3
O±ring
Engine Cover Bracket
± FUELFUEL INJECTOR ASSY (1AZ±FSE)
11±39
AVENSIS REPAIR MANUAL (RM1018E)

A79597
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
Gasket
38 (388, 28)
21 (210, 15)
9.5 (97, 84 in.
lbf)
30 (306, 22)
9.8 (100, 7)
30 (306, 22)
30 (306, 22)
Union to Connector
Tube Hose
Vacuum Hose
Intake Manifold
Insulator No. 1
Intake Air Control Valve Assy
Intake Manifold Insulator No. 2
Surge Tank
Stay No. 1
Engine Cover Bracket
Charcoal Canister Assy
Intake Manifold
x2 11±40
± FUELFUEL INJECTOR ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)