TOYOTA AVENSIS 2002 Repair Manual

A75340
Battery4
5

B12608
A76859
Hand±held Tester
± FUELFUEL SYSTEM (1AZ±FSE)
11±35
AVENSIS REPAIR MANUAL (RM1018E)
(b) When not using the hand±held tester
(1) Connect the positive (+) lead form the battery to ter-
minal 4 of the connector and connect the negative
(±) lead to terminal 5.
(2) Check that the pump operates.
3. CHECK FUEL PUMP OPERATION (HIGH PRESSURE)
(a) Remove the No. 1 engine cover.
(b) Start the engine.
(c) Using a sound scope, hear the operating sound of the
pump.
If there is no sound, replace the pump.
(d) Stop the engine.
(e) Reinstall the engine cover.
4. CHECK FUEL HIGH PRESSURE
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine.
(c) Select the active test mode on the hand±held tester.
(d) Perform the active test check the fuel high pressure at idle
to 3,000 rpm.
Fuel high pressure:
9.5 to 10.5 Mpa (97 to 107 kgf/cm
2, 1,380 to 1,520 psi)
If the pressure is not as specified, check the fuel pump, high
pressure fuel pump, fuel pressure sensor, wiring and fuel leak-
age.
(e) Stop the engine.
(f) Disconnect the hand±held tester.

110UZ±01
A75339
Fuel
Pump
Connector
B00679
Vinyl or Plastic Bag
11±30
±
FUEL FUEL SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
FUEL SYSTEM(1AZ±FSE)
PRECAUTION
1.PRECAUTION
(a)Before working on fuel system, disconnect negative (±) battery cable.
(b)Do not smoke or work near fire when handling the fuel system.
(c)Keep gasoline away from rubber or leather parts. 2.DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:

Do not disconnect any part of the fuel system until
you have discharged the fuel system pressure.

Even after discharging the fuel pressure, place a
shop rag over fittings as you separate them to reduce
risk of fuel spray on yourself or in the engine compart-
ment.
(a)Disconnect the fuel pump connector.
(b)Start the engine. After the engine has stopped, turn the ignition switch OFF.
(c)Disconnect the negative (±) battery cable.
(d)Connect the fuel pump connector.
3.FUEL SYSTEM
(a)When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these proce-
dures.
(1)Discharge the pressure in the fuel system. (See step 2)
(2) Disconnect the fuel pump tube. (See page 11±93)
(3) Drain the fuel that remained inside the fuel pump
tube.
(4) Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt.
(5) Place a tray under the vehicle or point of disconnec- tion to catch any fuel that may spill.

A60083
Fuel Pipe
Clamp No.1
A
A
B12941
B12944
A82344
Vinyl Bag or plastic Bag
± FUELFUEL SYSTEM (1AZ±FSE)
11±31
AVENSIS REPAIR MANUAL (RM1018E)
(b) Observe the following precautions when removing and
installing fuel injectors.
NOTICE:
Never reuse the O±ring.
(1) When installing a new O±ring to the injector, be
careful not to damage the injector.
(2) Coat the new O±ring with grease or gasoline before
installing. Never use engine oil, gear oil or brake oil.
(c) Observe these following precautions when disconnecting
the fuel tube connector (quick type).
(1) Remove the fuel pipe clamp No.1.
(2) Check that there is no dirt or mud on the pipe and
around the connector before disconnecting them.
Clean them if necessary.
(3) Disconnect the connector from the hose while
pinching part A with fingers as shown in the illustra-
tion.
(4) When the connector and the pipe are stuck, push
and pull the connector to release and pull the con-
nector out from the pipe carefully.
(5) Inspect that there is no dirt or mud on the sealing
surface of the disconnected pipe. Clean it away if
necessary.
(6) To prevent the disconnected pipe and connector
from being damaged and foreign objects from being
introduced, cover them with a vinyl or plastic bag.

B16534Push
B16535Pull
11±32
±
FUEL FUEL SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(d)Observe these precautions when connecting the fuel tube connectors (Quick Type):
(1)Check that there is no damage or foreign objects inthe connected part of the pipe.
(2)Match the axis of the connector with the axis of the pipe, and push into the connector until the connec-
tor makes a ºclickº sound. If the connection is tight,
apply little amount of fresh engine oil on the tip of the
pipe.
(3)After having finished the connection, check if the pipe and the connector are securely connected by
pulling on them.
(4)Check for fuel leaks.
4.CHECK FOR FUEL LEAKS
(a)Check that there are no fuel leaks after doing maintenance anywhere on t\
he fuel system. (See page 11±33)

110UE±01
A78267
Rear Seat Cushion Assy
Rear Floor Service Hole Cover
Fuel Pump Gauge Retainer
Fuel and Evaporation Vent Tube Sub±assy
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Fuel Suction Tube Set Gasket

Gasket
Gasket Exhaust Pipe Assy Front
Compression Spring
Floor Panel
Brace FrontCompression
Spring43 (440, 32)
30 (302, 22)
43 (440, 32)
± FUELFUEL TANK ASSY (DIESEL)
11±101
AVENSIS REPAIR MANUAL (RM1018E)
FUEL TANK ASSY (DIESEL)
COMPONENTS

A78268
N´m (kgf´cm, ft´lbf)
: Specified torqueParking Brake Cable
Assy No. 3 Parking Brake Cable
Assy No. 2 Fuel Tank Protector No. 1
Fuel Tank Band Breather Tube Fuel HoseFuel Tank to Filler Pipe Hose
Fuel Tank Band
5.4 (55, 48 in.
lbf)
5.4 (55, 48 in.
lbf)
5.4 (55, 48 in.
lbf)
40 (400, 29)
11±102
± FUELFUEL TANK ASSY (DIESEL)
AVENSIS REPAIR MANUAL (RM1018E)

A78269
Fuel Tank Return TubeFuel Evaporation
Tube Sub±assy No. 2
Fuel Tank Main Tube Sub±assy
Fuel Tank Assy
± FUELFUEL TANK ASSY (DIESEL)
11±103
AVENSIS REPAIR MANUAL (RM1018E)

110UF±01
A63024
A60575
Quick Connector
O±ring Nylon Tube
Tube Joint Clip
Fuel Suction Plate
A63025
11±104
±
FUEL FUEL TANK ASSY(DIESEL)
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE REAR SEAT CUSHION ASSY (See page 72±27)
2. REMOVE REAR FLOOR SERVICE HOLE COVER
(a) Remove the 4 screws and the rear floor service hole cover.
(b) Disconnect the connector. 3. DISCONNECT FUEL TANK RETURN TUBE
(a) Remove the tube joint clip and pull out the fuel tank returntube.
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.

Keep the plug free of foreign objects.

To protect the tube, cover it with a vinyl or a plastic
bag after checking.
4. DISCONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a) Pinch the tube connector then 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.

To protect the tube, cover it with a vinyl or a plastic
bag after checking.

When the connector and the pipe are stuck, push and
pull the connector to release. Pull out the connector
from the pipe carefully.

A63026
A60576
Fuel Tube
Connector Clip
Nylon Tube
O±ring Pipe
A62989
SST
A77883
±
FUEL FUEL TANK ASSY(DIESEL)
11±105
AVENSIS REPAIR MANUAL (RM1018E)
5.DISCONNECT FUEL EVAPOR ATION TUBE
SUB±ASSY NO.2
(a)Pinch the quick connector then pull out the fuel evapora-
tion tube sub±assy No. 2.
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.

To protect the tube, cover it with a vinyl or a plastic
bag after checking.

When the connector and the pipe are stuck, push and
pull the connector to release. Pull out the connector
from the pipe carefully.
6.REMOVE FUEL AND EVAPORATION VENT TUBE SUB±ASSY
(a)Using SST, loosen the retainer. SST09808±14010
(b)Remove the retainer.
(c)Pull out the fuel pump assembly.
CAUTION:
Be careful that the arm of the sender gauge should not
bent.
7.DRAIN FUEL
8.REMOVE FLOOR PANEL BRACE FRONT (See page 15±10)
9.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±10)
10. REMOVE FUEL TANK PROTECTOR NO.1
(a) Remove the 4 bolts and the fuel tank protector.

A77884
A77885
A77886
A77887
A78450
11±106
± FUELFUEL TANK ASSY (DIESEL)
AVENSIS REPAIR MANUAL (RM1018E)
11. REMOVE PARKING BRAKE CABLE ASSY NO.2
(a) Remove the 2 set bolts of the parking brake cable.
12. REMOVE PARKING BRAKE CABLE ASSY NO.3
(a) Remove the 2 set bolts of the parking brake cable.
13. DISCONNECT BREATHER TUBE FUEL HOSE
(a) Loosen the hose clamp and disconnect the fuel tank
breather hose.
14. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
(a) Loosen the hose clamp and disconnect the fuel tank to fill-
er pipe hose.
15. DISCONNECT FUEL TANK RETURN TUBE