TOYOTA AVENSIS 2003 Service Repair Manual

A78269
Fuel Tank Return TubeFuel Evaporation
Tube Sub±assy No. 2
Fuel Tank Main Tube Sub±assy
Fuel Tank Assy
±
FUEL FUEL TANK ASSY (DIESEL)
11±103
AVENSIS REPAIR MANUAL (RM1018E)
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110UF±01
A63024
A60575
Quick Connector
O±ring Nylon Tube
Tube Joint Clip
Fuel Suction Plate
A63025
11±104
±
FUELFUEL 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.
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A63026
A60576
Fuel Tube
Connector Clip
Nylon Tube
O±ring Pipe
A62989
SST
A77883
±
FUELFUEL TANK ASSY(DIESEL)
11±105
AVENSIS REPAIR MANUAL (RM1018E)
5.DISC ONNECT 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 EVAPOR ATION 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.
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A77884
A77885
A77886
A77887
A78450
11±106
±
FUEL FUEL 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
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A81588
31
22
A63387
Retainer
Fuel Tube Connector
O±ring
Pipe
A77890
A77894
A78270
±
FUEL FUEL 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.
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A77892
A77893
UpperFuel Tank
Rear
Hose Clamp
A81618
11±108
±
FUELFUEL TANK ASSY(DIESEL)
AVENSIS REPAIR MANUAL (RM1018E)
20.REMOVE FUEL TANK MAIN TUBE SUB±ASSY
(a)Unfasten the 4 claws, and remove the fuel tank main tube from the fuel tank.
21.INSTALL FUEL TANK MAIN TUBE SUB±ASSY
22.INSTALL FUEL EVAPOR ATION TUBE SUB±ASSY
NO.2
(a)Install the hose clamp as shown in the illustration.
23.INSTALL FUEL TANK RETURN TUBE
24.INSTALL FUEL TANK ASSY Torque: 40 N
m (400 kgf
cm, 29 ft
lbf)
25.CONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a)Push in the fuel tube connector to the pipe, and push upretainer to lock the claws.
NOTICE:

Check if there is any damage or foreign objects on the connected part.

After connecting, check if the quick connector and the pipe are securely\
connected by pulling
on them.
26.CONNECT FUEL TANK RETURN TUBE
27.CONNECT FUEL TANK TO FILLER PIPE HOSE
28.CONNECT BREATHER TUBE FUEL HOSE
29.INSTALL PARKING BRAKE CABLE ASSY NO.3 Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
30.INSTALL PARKING BRAKE CABLE ASSY NO.2 Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
31.INSTALL FUEL TANK PROTECTOR NO.1
Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
32.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±10)
33. ADD FUEL
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A63379
Mark
A62989
SST
A63380
Area
Arrow
Mark
A64697
A64698
±
FUEL FUEL TANK ASSY (DIESEL)
11±109
AVENSIS REPAIR MANUAL (RM1018E)
34. INSTALL FUEL AND EVAPORATION VENT TUBE
SUB±ASSY
(a) Align the arrow marks of the fuel pump bracket and the
fuel tank.
(b) Temporarily install the retainer.
(c) Mount SST to the retainer. SST 09808±14010
(d) Tighten the retainer until the arrow mark located on the re- tainer is positioned within the area shown in the illustra-
tion.
(e) Check that the arrow marks of the fuel pump bracket and fuel tank are aligned.
35. CONNECT FUEL EVAPORATION TUBE SUB±ASSY NO.2
(a) Push in the quick connector to the pipe until connector makes ºclickº sound.
NOTICE:

Check if there is any damage or foreign objects on the
connected part of the pipe.

After connecting, check if the pipe and the connector
are securely connected by pulling on them.
36. CONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a) Push in the quick connector to the pipe until connector makes ºclickº sound.
NOTICE:

Check if there is any damage or foreign objects on the
connected part of the pipe.

After connecting, check if the pipe and the connector
are securely connected by pulling on them.
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A64699
11±110
±
FUELFUEL TANK ASSY(DIESEL)
AVENSIS REPAIR MANUAL (RM1018E)
37.CONNECT FUEL TANK RETURN TUBE
(a)Connect the fuel tank return tube with the tube joint clip.
NOTICE:

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

Check that the connector is inserted securely.

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

After installing the tube joint clip, check that the con-
nector is not pulled off.
38.CHECK FOR FUEL LEAKS (See page 11±60)
39. CHECK FOR EXHAUST GAS LEAKS
40.INSTALL FLOOR PANEL BRACE FRONT (See page 15±10)
41. INSTALL REAR FLOOR SERVICE HOLE COVER
42.INSTALL REAR SEAT CUSHION ASSY (See page 72±27)
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110U6±01
A78441
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque Seat 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
±
FUEL FUEL TANK ASSY (GASOLINE)
11±89
AVENSIS REPAIR MANUAL (RM1018E)
FUEL TANK ASSY (GASOLINE)
COMPONENTS
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A78517
N´m (kgf´cm, ft´lbf) : Specified torque

Non±reusable part RHD:
Front Floor Footrest
1ZZ±FE/3ZZ±FE:
Floor Carpet Assy FrontClip
Compression Spring


Exhaust Pipe
Gasket
Exhaust Pipe Assy Front
Floor Panel Brace Front
43 (440, 33)
30 (302, 22)

Exhaust Pipe
Gasket
Compression Spring
43 (440, 32)
Exhaust Pipe Assy Center
43 (440, 32)

Exhaust Pipe
Gasket
Floor Panel Brace Front
30 (302, 22)
Compression Spring
43 (440, 32)

Exhaust Pipe
Gasket
1AZ±FE:
Exhaust Pipe Assy Center
43 (440, 32)

Exhaust Pipe
Gasket
Floor Panel Brace Front
30 (302, 22)
Compression Spring
43 (440, 32)

Exhaust Pipe
Gasket
1AZ±FE (Leaded Gasoline)
1AZ±FSE:
w/o HID Sensor:
11±90
±
FUEL FUEL TANK ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
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