TOYOTA AVENSIS 2002 Repair Manual

A77907
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
20 (204, 15)
Fuel Injector
Connector
EFI Fuel Pipe Clamp
Fuel Tube Sub±assy

Injector Vibration InsulatorDelivery Pipe No. 1
Spacer Fuel Delivery Pipe Sub±assy
Ventilation Hose No. 2
Fuel Injector Assy
Fuel Injector O±ring
± FUELFUEL INJECTOR ASSY (1AZ±FE)
11±25
AVENSIS REPAIR MANUAL (RM1018E)

110U1±01
A77908
Retainer
(at 4 places)
Insert
SST
Turn
Fuel Pipe
Clamp
A76220
O±ring
Nylon Tube HousingPipe
Retainer
A77909
11±26
±
FUEL FUEL INJECTOR ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
3.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±26) 4. DISCONNECT 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.
5. REMOVE FUEL DELIVERY PIPE SUB±ASSY
(a) Disconnect the ventilation hose.

A77910
(b)
(b)(c)
(c)
(c)
(c)
A78437
A77911
Delivery Pipe
No. 1 Spacer
Insulator
A77912
A78481
New O±ring
± FUELFUEL INJECTOR ASSY (1AZ±FE)
11±27
AVENSIS REPAIR MANUAL (RM1018E)
(b) Remove the 2 wire harness clamps.
(c) Disconnect the 4 fuel injector connectors.
(d) Remove the 2 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
delivery pipe.
(e) Remove the 2 delivery pipe No. 1 spacers and the 4 insu-
lators from the cylinder head.
6. REMOVE FUEL INJECTOR ASSY
(a) Pull out the 4 fuel injectors.
7. INSTALL FUEL INJECTOR ASSY
(a) Apply a light coat of spindle oil or gasoline to new O±rings
and install them to each fuel injector.

A77913
Turn
Push
A77914
Turn
A81621
Fuel Pipe
Clamp
Push
11±28
±
FUEL FUEL INJECTOR ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Apply a light coat of spindle oil or gasoline on the place where a fuel delivery pipe contacts the O±ring.
(c)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.
8.INSTALL FUEL DELIVERY PIPE SUB±ASSY
(a)Install 4 new insulators and the 2 delivery pipe No. 1 spacers to the cylinder head.
(b)Place the fuel delivery pipe and the 4 fuel injectors togeth- er to the cylinder head.
NOTICE:
Be careful not to drop the fuel injectors when installing the
fuel delivery pipe.
(c)Temporarily install 2 bolts which are used to secure the fuel delivery pipe to the cylinder head.
(d)Check that the fuel injectors rotate smoothly.
If the fuel injectors do not rotate smoothly, the probable cause
is incorrect installation of O±ring. Replace with the O±ring.
(e)Tighten the 2 bolts. Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(f)Connect the 4 fuel injector connectors.
(g)Install the 2 wire harness clamps.
(h)Connect the ventilation hose.
9.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.
10.INSTALL AIR CLEANER CAP SUB±ASSY
11.CHECK FOR FUEL LEAKS (See page 11±19)
12.INSTALL ENGINE COVER SUB±ASSY NO.1 (See page 10±26)

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)

A79598
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Fuel Injector Seal
Gasket
13 (127, 9)
19 (194, 14)

O±ring
E±ring

Fuel Injector
Back±up Ring No. 3

Fuel Injector
Back±up Ring No. 2
Fuel Injector
Back±up Ring No. 1
Injector Assy
Fuel Delivery
Pipe Sub±assy
Nozzle Holder Clamp
x5
± FUELFUEL INJECTOR ASSY (1AZ±FSE)
11±41
AVENSIS REPAIR MANUAL (RM1018E)

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