vin TOYOTA AVENSIS 2002 Manual PDF
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2002, Model line: AVENSIS, Model: TOYOTA AVENSIS 2002Pages: 1690, PDF Size: 32.77 MB
Page 791 of 1690
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.
Page 803 of 1690
A77888
1
2
3
Retainer
Pinch
Pinch
2
A63387
Retainer
Pipe
O±ring Fuel Tube Connector
A77889
2
Pinch1
Pinch1
A60576
Nylon Tube
Pipe
O±ringFuel Tube
Connector Clip
Fuel Tube
Connector
A77890
± FUELFUEL TANK ASSY (GASOLINE)
11±97
AVENSIS REPAIR MANUAL (RM1018E)
19. 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 plastic bag.
When the pipe and connector are stuck, push and pull
the connector to release. Pull out the connector from
the pipe.
20. DISCONNECT FUEL EVAPORATION TUBE
SUB±ASSY NO.2
(a) Pinch the fuel tube connector clip and pull out the fuel
evaporation 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 plastic bag.
When the pipe and connector are stuck, push and pull
the connector to release. Pull out the connector from
the pipe.
21. REMOVE FUEL TANK ASSY
(a) Set a transmission jack to the fuel tank.
(b) Remove the 4 bolts and the 2 fuel tank bands, and then
remove the fuel tank.
Page 811 of 1690
A79148
SST
A79143
SST
11±70
± FUELINJECTION OR SUPPLY PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
24. REMOVE FUEL INLET PIPE SUB±ASSY
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and injection pump with vinyl tape to prevent dust from be-
ing introduced.
(a) Remove the wire bracket and slide the engine wire.
(b) Using SST, remove the fuel inlet pipe from the common
rail.
SST 09023±12700
(c) Using SST, remove the fuel inlet pipe from the injection
pump.
SST 09023±12700
25. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts, then remove the 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.
26. REMOVE INJECTION PIPE SUB±ASSY NO.2
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
27. REMOVE INJECTION PIPE SUB±ASSY NO.3
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
28. REMOVE INJECTION PIPE SUB±ASSY NO.4
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
Page 813 of 1690
A62779SST
A79153
A62166
SST
11±72
±
FUEL INJECTION OR SUPPLY PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Using SST, remove the injection pump drive pulley. SST09950±50013 (09951±05010, 09952±05010, 09953±05020, 09954±05021)
36.REMOVE INJECTION OR SUPPLY PUMP ASSY
(a)Remove the 2 nuts and the injection pump.
37.INSTALL INJECTION OR SUPPLY PUMP ASSY Torque: 21 N m (210 kgf cm, 15 ft lbf)
38.INSTALL INJECTION PUMP DRIVE PULLEY
(a)Using SST, install the pulley nut. SST09960±10010 (09962±01000, 09963±01000)
Torque: 64 N m (650 kgf cm, 47 ft lbf)
39.INSTALL WATER INLET(See page 16±50)
40.INSTALL OIL LEVEL GAGE GUIDE(See page 17±22)
41. INSTALL INTAKE MANIFOLD INSULATOR NO.1 Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
42. INSTALL INJECTION PIPE SUB±ASSY NO.1
NOTICE:
When assembling the pipes, perform the operation with the
engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and vinyl tape from the common rail.
(b) Temporarily install the injection pipe.
Page 815 of 1690
A79149
SST
30 cm
(11.81 in.)
11±74
±
FUEL INJECTION OR SUPPLY PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
46.INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:
In case of having the injection pump replaced, must
replace the fuel inlet pipe, too.
When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a)Temporarily install the fuel inlet pipe.
(b)Using SST, tighten the nut of the fuel inlet pipe to the com-
mon rail side.
SST09023±12700
Torque:
42 Nm (428 kgf cm, 31 ft lbf) for a used pipe using SST
46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using
SST
31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST
34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
(c)Using SST, tighten the nut of the fuel inlet pipe to the injec-
tion pump side.
SST09023±12700
Torque:
42 Nm (428 kgf cm, 31 ft lbf) for a used pipe using SST
46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using
SST
31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST
34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
47.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307) SST 09960±10010 (09962±01000, 09963±01000)
48.INSTALL TIMING BELT(See page 14±307)
49.CHECK VALVE TIMING(See page 14±307)
50.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
51. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Torque:
37 Nm (375 kgf cm, 27 ft lbf) for 14mm head bolt
64 N m (650 kgf cm, 47 ft lbf) for 17mm head bolt
Page 819 of 1690
110U8±01
A79143
SST
11±60
±
FUEL INJECTOR ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
Each injector assembly has a characteristic fuel injecting behavior. The ECM stores compensation codes
which are used to optimize fuel injection for the injectors. When replacing t\
he injector assembly, a compensa-
tion code for the new injector assembly must be set to the ECM.
1.REMOVE VACUUM RESERVOIR SUB±ASSY
(a)Disconnect the 2 vacuum hoses and the connector.
(b)Remove the 2 bolts and the vacuum reservoir.
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
4.REMOVE AIR CLEANER ASSY
(a)Disconnect the connector.
(b)Remove the air cleaner cap with the air cleaner hose.
(c)Remove the air cleaner filter element.
(d)Remove the 3 bolts and the air cleaner case.
5.REMOVE AIR TUBE NO.1 (See page 14±270) 6. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts and 2 upper infection pipe clampsfrom 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 plas-
tic bag.
7. REMOVE INJECTION PIPE SUB±ASSY NO.2
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
8. REMOVE INJECTION PIPE SUB±ASSY NO.3 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
9. REMOVE INJECTION PIPE SUB±ASSY NO.4 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
10. REMOVE TIMING BELT NO.2 COVER
(a) Remove the 7 bolts and 7 seal washers, then remove the timing belt cover\
.
Page 820 of 1690
A09656
A79144
A80110
±
FUEL INJECTOR ASSY(1CD±FTV)
11±61
AVENSIS REPAIR MANUAL (RM1018E)
11.REMOVE NOZZLE HOLDER SEAL
(a)Using a screwdriver, pry out the 4 nozzle holder seals.
12.REMOVE CYLINDER HEAD COVER SUB±ASSY
(a)Remove the 10 bolts and the cylinder head cover.
13.REMOVE NOZZLE LEAKAGE PIPE ASSY
(a)Remove the union bolt and the 4 hollow screws, then re-
move the nozzle leakage pipe and the 5 gaskets.
NOTICE:
When removing then nozzle leakage pipe, place the shop
rag under the pipe to protect the cylinder head from the fuel
remaining inside the pipe.
14.REMOVE NOZZLE HOLDER CLAMP
(a)Remove the 4 bolts, 4 washers and 4 nozzle holder clamps.
15.REMOVE INJECTOR ASSY
(a)Remove the 4 injectors from the cylinder head.
(b)Remove the O±rings and back±up rings from each injector.
(c)Remove the 4 nozzle seats from the cylinder head.
16.REGISTRATION OF INJECTOR COMPENSATION CODE (See page 05±528)
HINT:
Each injector assembly has a characteristic fuel injecting behavior. When replacing the injector assembly,
store them in correct order so that they can be returned to the original\
locations when re±assembling. 17. INSTALL INJECTOR ASSY
(a) Install 4 new nozzle seats to the cylinder head.
Page 823 of 1690
A79147
SST
30 cm
(11.81 in.)
11±64
±
FUEL INJECTOR ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
20.INSTALL NOZZLE HOLDER SEAL
(a)Install new 4 nozzle holder seals.
21.INSTALL TIMING BELT NO.2 COVER(See page 14±307) 22. INSTALL INJECTION PIPE SUB±ASSY NO.1
NOTICE:
In case of having the injectors replaced, must replace
the injection pipes, too.
When assembling the pipes, perform the operation
with the engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and
vinyl tape from the common rail.
(b) Temporarily install the injection pipe.
(c) Using SST, tighten the nut of the injection pipe to the com- mon rail.
SST 09023±12700
Torque:
42 Nm (428 kgf cm, 31 ft lbf) for a used pipe using SST
46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using
SST
31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST
34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(d) Using SST, tighten the nut of the injection pipe to the injec- tor.
SST 09023±12700
Torque:
42 Nm (428 kgf cm, 31 ft lbf) for a used pipe using SST
46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using
SST
31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST
34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e) Install the 2 upper injection pipe clamps with the 2 nuts. Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
Page 889 of 1690
550Z4±01
I35326
I35327
I35328
55±82
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55±38) SST 07110±58060 (07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070, 07117±88080)
2. DISCONNECT COOLER REFRIGERANT SUCTIONHOSE NO.1
(a) Remove the bolt and disconnect the cooler refrigerant suction hose No.1 from the w/pulley compressor assy.
(b) Remove the O±ring from the cooler refrigerant suction hose No.1.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
3. DISCONNECT COOLER REFRIGERANT DISCHARGE
HOSE NO.1
(a) Remove the bolt and disconnect the cooler refrigerant discharge hose No.1 from the w/pulley compressor assy.
(b) Remove the O±ring from the cooler refrigerant discharge
hose No.1.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
4.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±105)
5.REMOVE ENGINE ROOM COVER SIDE (See page 14±105)
6.REMOVE ENGINE UNDER COVER RH (See page 14±105)
7.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010 8. REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 4 bolts and the w/pulley compressor assy.
9. INSPECT COMPRESSOR OIL
(a) When replacing the w/pulley compressor assy with a new one, after gradually \
removing the refrigerant gas from the service valve, drain the following amount of oil from the new w\
/pulley compressor assy
before installation.
Standard:
(Oil capacity inside new w/pulley compressor assy: 90 + 15 cc (3.0 + 0.5 fl. oz.) ) ± (Remaining
oil amount in the removed w/pulley compressor assy) = (Oil amount to be r\
emoved when replac-
ing)
Page 890 of 1690
I35328
(1)(2)
(3)
(4)
I35327
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1AZ±FE)
55±83
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:
When checking the compressor oil level, observe the precautions on the c\
ooler removal/instal-
lation.
Since compressor oil remains in the pipes of the vehicle, if a new w/pulley c\
ompressor assy
is installed without removing some oil inside, the oil amount becomes ex\
cessive, preventing
heat exchange in the refrigerant cycle and causing refrigerant failure.
If the remaining oil in the removed w/pulley compressor assy is too smal\
l in volume, check for
oil leakage.
Be sure to use ND±OIL 8 for compressor oil.
10. INSTALL W/PULLEY COMPRESSOR ASSY
(a) Install the w/pulley compressor assy with the 4 bolts.Torque: 29 N m (300 kgf cm, 21 ft lbf)
NOTICE:
Tighten the bolts in the order shown in the illustration to
install the w/pulley compressor assy.
(b) Connect the connector.
11.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
12. INSTALL COOLER REFRIGERANT DISCHARGEHOSE NO.1
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O±ring and the fitting surface of the w/pulley compressor assy.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the cooler refrigerant discharge hose No.1.
(d) Install the cooler refrigerant discharge hose No.1 on the w/pulley compressor assy with the bolt.
Torque: 9.8 N m (100 kgf cm, 87 in. lbf)
13. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O±ring and the
fitting surface of the w/pulley compressor assy.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the cooler refrigerant suction hose
No.1.