TOYOTA AVENSIS 2002 Repair Manual

A79575
Fuel Injector
Back±up Ring No. 1
Fuel Injector
Back±up Ring No. 2
O±ring
Fuel injector
Back±up Ring No. 3
A79576
A79570
SST
11±54
± FUELFUEL PUMP ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL FUEL PIPE SUB±ASSY NO.1
(a) Attach a new O±ring, fuel injector back±up ring No. 1, No.
2 and No. 3 to the fuel pipe sub±assy No.1.
(b) Apply a small amount of fuel on the O±ring and install the
fuel pipe sub±assy No. 1 to the fuel pump assy and the
fuel delivery pipe sub±assy.
NOTICE:
Be careful not to damage both the sealing surfaces of the
fuel delivery pipe and the fuel pump when installing the fuel
pipe No.1.
(c) Tighten the nut by hand to attach the fuel pipe sub±assy
No. 1 to the fuel pump assy.
(d) In order to secure the fuel pipe sub±assy No. 1 to the fuel
delivery pipe sub±assy, tighten the 2 bolts to the specified
torque.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
(e) Clamp the union bolt on the fuel pump assy with a 21 mm
wrench and tighten the nut with the specified torque to se-
cure the fuel pipe sub±assy No. 1 to the fuel pump assy
using a 19 mm union±nut wrench.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
11. INSTALL FUEL PRESSURE PULSATION DAMPER
ASSY
(a) Install the fuel pulsation damper assy to the fuel pump
assy after fitting new 2 gaskets and fuel tube sub±assy
between those assys.
(b) Using SST, install the fuel pressure pulsation damper
assy to the fuel pump assy.
SST 09617±24011
Torque: 33 N
m (331 kgf
cm, 24 ft
lbf)
(c) Connect the fuel tube sub±assy.

±
FUEL FUEL PUMP ASSY(1AZ±FSE)
11±55
AVENSIS REPAIR MANUAL (RM1018E)
12.INSTALL ENGINE COVER BRACKET
(a)Install the engine cover bracket with the bolt.
Torque: 38 N
m (388 kgf
cm, 28 ft
lbf)
13.INSTALL AIR CLEANER CAP SUB±ASSY (See page 10±44)
14. CHECK FOR FUEL LEAKS
15. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
16. INSTALL RADIATOR SUPPORT OPENING COVER

110U3±01
A78441
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torqueSeat Fixed Type:
Rear Seat Cushion Assembly
Rear Floor Service Hole Cover
Fuel Pump Connector
Fuel Evaporation Tube
Sub±assy No. 2 Fuel Tank Main Tube
Sub±assy
Tube Joint Clip
Fuel Pump Gauge Retainer
Fuel Suction
w/ Pump & Gage Tube Assy

Fuel Suction Tube
Set Gasket x4
1AZ±FSE:
Fuel Tank Return Tube
11±84
± FUELFUEL PUMP ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
FUEL PUMP ASSY (GASOLINE)
COMPONENTS

110U4±01
A78442
(a)
A78443
1
2
Tube Joint Clip
A60575
Nylon Tube
Fuel Tube Joint
O±ring Tube Joint Clip
Fuel Suction Plate
±
FUEL FUEL PUMP ASSY(GASOLINE)
11±85
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE
HINT:

1ZZ±FE/3ZZ±FE: 11±1

1AZ±FE: 11±15

1AZ±FSE: 11±30
2.REMOVE REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 72±32)
3. REMOVE REAR FLOOR SERVICE HOLE COVER
(a) Remove the 4 screws, and then remove the rear floor ser-vice hole cover.
(b) Disconnect the fuel pump connector.
4. DISCONNECT FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE)
(a) Remove the tube joint clip, and pull out the fuel return 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 fuel tube joint has an
O±ring which seals the pipe and 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 and pull the connector out
carefully.

A78444
2
1
Pinch1
Pinch
A75650
Tube Connector
Pipe O±ring Nylon Tube
A78445
2
Pinch
Pinch1
1
A65059
Nylon TubeO±ringFuel Tube
Connector Clip
Fuel Tube
ConnectorPipe
A78446
SST
Rib
11±86
± FUELFUEL PUMP ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
5. DISCONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a) Pinch the tube connector and 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 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 and pull the connector out
carefully.
6. 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 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 and pull the connector out
carefully.
7. REMOVE FUEL SUCTION W/PUMP & GAGE TUBE
ASSY
(a) Using SST, loosen the fuel pump gauge retainer.
SST 09808±14010
NOTICE:
Do not use other tools in this operation. Damage to the fuel
pump gauge retainer and the fuel tank may result.
HINT:
A rib on the fuel pump gauge retainer can be fitted into a tip of
the SST.

A78447
A78448
Triangle Mark
Matchmark
A78446
SST
Rib
A78449
Arrow Mark
± FUELFUEL PUMP ASSY (GASOLINE)
11±87
AVENSIS REPAIR MANUAL (RM1018E)
(b) Remove the fuel pump gauge retainer.
(c) Remove the fuel suction w/ pump & gage tube.
NOTICE:
Be careful that the arm of the fuel sender gage should not
be bent.
(d) Remove the gasket from the tank.
8. INSTALL FUEL SUCTION W/PUMP & GAGE TUBE
ASSY
(a) Install a new gasket to the fuel tank.
(b) Install the fuel suction w/ pump & gage tube.
NOTICE:
Be careful that the arm of the fuel sender gage should not
be bent.
(c) Align the triangle mark of the fuel suction w/ pump & gage
tube with the matchmark location the fuel tank.
(d) Temporarily install the fuel pump gauge retainer.
(e) Using SST, tighten the fuel pump gauge retainer until the
arrow mark is aligned with the center mark on the fuel
tank.
SST 09808±14010
NOTICE:
Do not use other tools in this operation. Damage to the fuel
pump gauge retainer and the fuel tank may result.
HINT:
A rib on the fuel pump gauge retainer can be fitted into a tip of
the SST.
(f) Check that the arrow mark and center mark are aligned
as shown in the illustration.

A81614
Push
A81615
Push
A81616
Tube Joint Clip
Collar
2
1
11±88
±
FUEL FUEL PUMP ASSY(GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
9.CONNECT FUEL EVAPORATION TUBE SUB±ASSY NO.2
(a)Push in the fuel tube 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 fuel tube connector and
the pipe are securely connected by pulling on them.
10.CONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a)Push in the fuel tube 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 fuel tube connector and
the pipe are securely connected by pulling on them.
11.C ONNECT FUEL TANK RETURN TUBE (1AZ±F SE
ENGINE TYPE)
(a)Install in the fuel return tube with the tube joint clip.
NOTICE:

Check that there is no scratch or foreign objects on
the connecting part.

Check that the fuel tube joint is inserted securely.

Check that the tube joint clip is on the collar of the fuel
tube joint.

After installing the tube joint clip, check that the fuel
tube joint has not been pulled off.
12.CHECK FOR FUEL LEAKS
HINT:

1ZZ±FE/3ZZ±FE: 11±5

1AZ±FE: 11±19

1AZ±FSE: 11±33
13.INSTALL REAR FLOOR SERVICE HOLE COVER
14.INSTALL REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 72±32)

110UY±01
Fuel Tube Connector
A50710
Fuel Tube Connector
SST
(Hose)
B12947
SST (Hose)SST
(Clamp)
Vinyl Tube SST (Union)
O±Ring
A51875
11±22
±
FUEL FUEL SYSTEM(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1.INSPECT FUEL INJECTOR ASSY
(a)Inspect injector resistance (1)Using an ohmmeter, measure the resistance be-tween the terminals.
Resistance: 13.4 to 14.2 at 20
C (68
F)
If the resistance is not as specified, replace the injector.
(b)Inspect injector inspection
CAUTION:
This test involves high±pressure fuel and electricity. Take
every precaution regarding safe handling of both the fuel
and the electricity. Preform this test in a safe area, and
avoid any sparks or flame. Do not smoke.
(1)Obtain new No. 1 fuel pipe (part No. 23901±0H040)and remove the fuel tube connector from the pipe.
(2)Install the fuel tube connector to SST (hose), then connect the tube connector and the fuel pipe.
SST09268±41047 (95336±08070)
CAUTION:
Connect the fuel tube connector (quick type) after observ-
ing the precautions to prevent fuel from spraying.
(3)Install the O±ring to the injector.
(4)Connect SST (union and hose) to the injector, andhold the injector and the union with SST (clamp)
SST09268±41047 (09268±41110, 09268±41300, 95336±08070)
(5)Put the injector into a graduated cylinder.
CAUTION:
Install a suitable vinyl tube onto the injector to contain gas-
oline spray. (6)Operate the fuel pump.(See Page 11±19)

SST
A50700
B00069
A16628A32859
± FUELFUEL SYSTEM (1AZ±FE)
11±23
AVENSIS REPAIR MANUAL (RM1018E)
(7) Connect SST (wire) to the injector and the battery
for 15 seconds, and measure the injection volume
with a graduated cylinder. Test each injector 2 or 3
times.
SST 09842±30080
Injection volume:
Injection volumeDifference between each injector
60 to 73 cm3
(3.6 to 4.5 cu in.)
in 15 seconds13 cm3 (0.9 cu in.) or less
NOTICE:
Always do the switching at the battery side.
If the injection volume is not as specified, replace the injector.
(c) Inspect leakage
(1) In the condition above, disconnect the test probes
of SST (wire) from the battery and check the fuel
leakage from the injector.
Fuel drop: 1 drop or less in 12 minutes
2. INSPECT FUEL PUMP
(a) Insect fuel pump resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance: 0.2 to 3.0
at 20C (68F)
(b) Inspect fuel pump operation
(1) Apply battery voltage to both the terminals. Check
that the pump operates.
NOTICE:

These tests must be done quickly (within 10 seconds)
to prevent damage to the pump.

Keep fuel pump as far away from the battery as pos-
sible.

Always do the switching at the battery side.

110UX±01
Fuel Tube Connector
A50710
A60083
Fuel Pipe
Clamp No.1
AA
B12941
±
FUEL FUEL SYSTEM(1AZ±FE)
11±19
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1.CHECK FUEL PRESSURE
(a)Discharge the pressure in the fuel system and take pre-
cautions for possible fuel spillage.(See page 11±15)
(b) Check that the battery voltage is above 12 V.
(c) Disconnect the negative (±) battery cable.
(d) Pull out the connecter from a new fuel tube.
HINT:
Part No. 23901±0H040
(e) Remove the fuel pipe clamp No.1 from the fuel tube con- nector.
(f) Disconnect the fuel tube connector from the fuel pipe while pinching part A with fingers as shown in the illustra-
tion.
CAUTION:

Do not disconnect the fuel tube connector (quick
type) until after you have discharged the fuel system
pressure and taken appropriate steps to prevent fuel
spillage.

There may be remained pressure in the fuel lines after
discharging the pressure.
Take precautions to prevent fuel from spraying on
you or your clothing or inside the engine compart-
ment.