fuel pump TOYOTA AVENSIS 2002 User Guide
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2002, Model line: AVENSIS, Model: TOYOTA AVENSIS 2002Pages: 1690, PDF Size: 32.77 MB
Page 359 of 1690
A79143
SST
A09656
A79144
±
ENGINE MECHANICAL CAMSHAFT(1CD±FTV)
14±319
AVENSIS REPAIR MANUAL (RM1018E)
26.REMOVE INJECTION PIPE SUB±ASSY NO.1
(See page 11±60)
(a) Remove the 2 nuts and 2 upper infection pipe clamps
from the intake manifold.
(b) Using SST, remove the injection pipe from the common rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or a
plastic bag.
27.REMOVE INJECTION PIPE SUB±ASSY NO.2(See page 11±60) SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
28.REMOVE INJECTION PIPE SUB±ASSY NO.3(See page 11±60) SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
29.REMOVE INJECTION PIPE SUB±ASSY NO.4(See page 11±60) SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
30. REMOVE VACUUM PUMP ASSY
(a) Remove vacuum hose.
(b) Remove vacuum pump oil hose.
(c) Remove the 2 bolts and the vacuum pump assembly.
31. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
32. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Remove the 10 bolts, the cylinder head cover and thegasket.
Page 416 of 1690
A77374
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part Gasket
Cylinder Head Cover Sub±assy
11 (115, 8.0)
Ventilation Hose No. 1 Gasket
Fuel Tube Sub±assy Gasket Fuel Pipe
Sub±assy No. 1
Fuel Pressure
Pulsation Damper
Assy
Fuel Pump Assy
Gasket14 (143, 10)
Ignition Control
9.0 (90, 80 in.lbf)
9.0 (90, 80 in.lbf)
O±ring
Ventilation Hose No. 2
33 (331, 24)
25 (255, 18)
Fuel Pipe No. 1
Fuel Injector
Back±up Ring No. 1
Fuel Injector Back±up
Ring No. 3 Fuel Injector
Back±up Ring No. 2
30 (306, 22)
14±220
± ENGINE MECHANICALCHAIN SUB±ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
Page 432 of 1690
141BB±01
A77292
A77299
14±160
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2. REMOVE FRONT WHEEL RH
3. REMOVE RADIATOR SUPPORT OPENING COVER
4. REMOVE ENGINE ROOM COVER SIDE
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±19)
8. DRAIN ENGINE OIL
(a) Install a new gasket and the drain plug after draining engine oil. Torque: 25 N m (255 kgf cm, 18 ft lbf)
9.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 14±121)
10.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
11.REMOVE GENERATOR ASSY (See page 19±20)
12.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
13. SEPARATE VANE PUMP ASSY
(a) Remove the 2 bolts and separate the vane pump.
14. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils. 15. SEPARATE RETURN TUBE SUB±ASSY
(a) Remove the 3 bolts and separate the return tube asshown in the illustration.
Page 439 of 1690
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FE)
14±167
AVENSIS REPAIR MANUAL (RM1018E)
69.INSTALL CHAIN VIBRATION DAMPER NO.1
Torque: 9.0 N m (92 kgf cm,80 in. lbf)
70.INSTALL CHAIN SUB±ASSY (See page 14±139)
71.INSTALL TIMING CHAIN GUIDE
Torque: 9.0 N m (92 kgf cm,80 in. lbf)
72.INSTALL CHAIN TENSIONER SLIPPER Torque: 19 N m (195 kgf cm,15 ft lbf)
73.INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14±171)
74.INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY (See page 14±139)
75.INSTALL V±RIBBED BELT TENSIONER ASSY (See page 14±139)
76.INSTALL OIL PAN SUB±ASSY (See page 14±139)
77.INSTALL CRANKSHAFT POSITION SENSOR (See page 18±17)
78.INSTALL CRANKSHAFT PULLEY (See page 14±139) SST09213±54015 (91651±60855), 09330±00021
79.INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14±139)
80.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque: 52 N m (530 kgf cm,38 ft lbf)
81.INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
82.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
83.INSTALL ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING) Torque: 9.0 N m (92 kgf cm,80 in. lbf)
84.INSTALL COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm,80 in. lbf)
85.INSTALL ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
Torque: 9.0 N m (92 kgf cm,80 in. lbf)
86.INSTALL ENGINE WIRE
87.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgf cm,71 in. lbf)
88.IN STALL COOL ER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITION ER)
STEERING POSITION TYPE)
89.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N m (82 kgf cm,71 in. lbf)
90.INSTALL IGNITION COIL ASSY
Torque: 9.0 N m (92 kgf cm,80 in. lbf)
91.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N m (71 kgf cm,62 in. lbf)
92.INSTALL VANE PUMP ASSY
Torque: 37 N m (377 kgf cm,27 ft lbf)
93.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
94.INSTALL GENERATOR ASSY (See page 19±20)
95.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
96.ADD COOLANT (See page 16±19)
97. ADD ENGINE OIL
98.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
99. CHECK FOR ENGINE OIL LEAKS
100. CHECK FOR FUEL LEAKS
101. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
Page 440 of 1690
141BO±01
A77339
A77292
14±254
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±19)
8.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil. Torque: 25 N m (255 kgf cm,18 ft lbf)
9.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
10.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
11.SEPARATE FUEL TUBE SUB±ASSY (See page 11±33)
12.REMOVE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
13.REMOVE FUEL PUMP ASSY (See page 11±52)
14.REMOVE FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
15.REMOVE GENERATOR ASSY (See page 19±20)
16.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
17. SEPARATE VANE PUMP ASSY
(a) Remove the 2 bolts and separate the vane pump.
18. REMOVE IGNITION COIL ASSY
(a) Remove the 4 bolts and 4 ignition coils.
Page 448 of 1690
14±262
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
86.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
87. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
88. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
89. INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
90. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
91. INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
92. INSTALL IGNITION COIL ASSY Torque: 9.0 N m (92 kgf cm, 80 in. lbf)
93.INSTALL FUEL PUMP ASSY (See page 11±52)
94.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
95.INSTALL FUEL TUBE SUB±ASSY (See page 11±33)
96.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
97. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
98. INSTALL VANE PUMP ASSY
Torque: 37 N m (377 kgf cm, 27 ft lbf)
99.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
100.INSTALL GENERATOR ASSY (See page 19±20)
101.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
102.ADD COOLANT (See page 16±31)
103. ADD ENGINE OIL
104.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
105. CHECK FOR ENGINE OIL LEAKS
106. CHECK FOR FUEL LEAKS
107. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
Page 450 of 1690
A79430
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part
52 (530, 38)
52 (530, 38)
7.5 (76, 66 in.lbf)
7.5 (76, 66 in.lbf)
52 (530, 38)
25 (255, 18)
25 (255, 18)
43 (440, 32)
18 (178, 13)
30 (302, 22)
7.5 (76, 66 in.lbf)
7.5 (76, 66 in.lbf)
43 (440, 32) Gasket
Gasket Gasket
Injector DriverEngine Mounting Insulator
Sub±assy RH
Vacuum Reservoir Sub±assy
w/ Cold Area:
Heater Bracket
Radiator Hose Inlet
Radiator Hose Outlet
Fuel Filter Assy Air Tube No. 1
Air Tube No. 2
Exhaust Pipe Assy Front
Floor Panel Brace Front
w/ Cold Area:
Exhaust PIpe Assy
Union To Connector Tube Hose
w/ Cold Area:
Heater Pump Assy
Compression Spring
Compression Spring
8.3 (85, 73 in.lbf)
25 (255, 18)
5.0 (51, 44 in.lbf)
± ENGINE MECHANICALCYLINDER HEAD GASKET (1CD±FTV)
14±327
AVENSIS REPAIR MANUAL (RM1018E)
Page 453 of 1690
A79431
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part
* Use SST
5.0 (51, 44 in.lbf)
* 31 (316, 23)
34 (347, 25)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2
Injection Pipe Sub±assy
* 42 (428, 31)
46 (469, 34)
Fuel Inlet Pipe
Sub±assy
O±ring
43 (438, 32)
21 (214, 15)
Common Rail Assy
Fuel Hose No. 4
Camshaft Position Sensor
Set Key Camshaft Timing Pulley
88 (899, 65)
Vacuum Pump Assy
8.8 (90, 78 in.lbf)
* 42 (428, 31)
46 (469, 34)
14±330
± ENGINE MECHANICALCYLINDER HEAD GASKET (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
Page 455 of 1690
141CA±01
14±332
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER LH
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.DRAIN ENGINE COOLANT (See page 16±44)
6.DRAIN ENGINE OIL (See page 14±342)
7. REMOVE RADIATOR SUPPORT OPENING COVER
8. REMOVE ENGINE ROOM COVER SIDE
9. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
10.REMOVE VACUUM RESERVOIR SUB±ASSY (See page 13±11)
11.REMOVE AIR CLEANER ASSY (See page 14±286)
12. REMOVE BATTERY
13.REMOVE AIR TUBE NO.2 (See page 14±286)
14.REMOVE AIR TUBE NO.1(See page 14±270)
15.REMOVE INJECTOR DRIVER (See page 14±286)
16. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
17.REMOVE GENERATOR V BELT (See page 14±269)
18.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
19.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
20.REMOVE CRANKSHAFT PULLEY(See page 14±307)
SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
21.REMOVE IDLER PULLEY SUB±ASSY(See page 14±307)
22.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
23.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
24. REMOVE TIMING BELT GUIDE
25.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
26.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
27.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
28.REMOVE TIMING BELT(See page 14±307)
HINT:
If re±using the timing belt, draw a direction arrow on the timing belt (\
in direction of engine revolution), and
place matchmarks on the pulleys and the timing belt.
29.REMOVE FUEL FILTER ASSY (See page 11±82)
30.REMOVE HEATER PUMP ASSY (W/ COLD AREA) (See page 13±11)
31.REMOVE HEATER BRACKET (W/ COLD AREA) (See page 13±11)
32.REMOVE FLOOR PANEL BRACE FRONT(See page 15±10)
33.REMOVE EXHAUST PIPE ASSY FRONT(See page 15±10)
34.REMOVE EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
35. DISCONNECT RADIATOR HOSE INLET
36. DISCONNECT HEATER INLET WATER HOSE
37. DISCONNECT HEATER OUTLET WATER HOSE
38. DISCONNECT FUEL PIPE TO FUEL TUBE FUEL HOSE
39. DISCONNECT OIL COOLER HOSE
40.REMOVE TURBO INSULATOR NO.2 (See page 13±11)
41.REMOVE TURBO INSULATOR NO.1 (See page 13±11)
Page 456 of 1690
A79148
SST
A79143
SST
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±333
AVENSIS REPAIR MANUAL (RM1018E)
42.REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
43.REMOVE MANIFOLD STAY NO.2 (See page 13±11)
44.REMOVE MANIFOLD STAY (See page 13±11)
45.REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
46.REMOVE TURBOCHARGER STAY (See page 13±11)
47.REMOVE TURBO WATER HOSE NO.1 (See page 13±11)
48.REMOVE TURBO WATER HOSE NO.2 (See page 13±11)
49.SEPARATE TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
50.REMOVE TURBOCHARGER SUB±ASSY (See page 13±11)
51.REMOVE CAMSHAFT POSITION SENSOR (See page 10±63)
52.REMOVE CAMSHAFT TIMING PULLEY (See page 14±318)
SST 09960±10010 (09962±01000, 09963±01000)
53. REMOVE FUEL INLET PIPE SUB±ASSY
(a) Using SST, remove the fuel inlet pipe from the commonrail side.
SST 09023±12700
(b) Using SST, remove the fuel inlet pipe from the pump side.
SST 09023±12700
NOTICE:
After removing the fuel pipe, cover the common rail and the
injector mounting holes with vinyl tape to prevent dust
from being introduced.
54. REMOVE INJECTION PIPE SUB±ASSY NO.1 (See page 11±60)
SST 09023±12700
(a) Remove the 2 nuts and 2 upper infection pipe clamps
from the intake manifold.
(b) Using SST, remove the injection pipe from the common rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector
side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or a
plastic bag.
55. REMOVE INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
56. REMOVE INJECTION PIPE SUB±ASSY NO.3
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.