gas type TOYOTA AVENSIS 2003 Service User Guide

110U4±01
A78442
(a)
A78443
1
2
Tube Joint Clip
A60575
Nylon Tube
Fuel Tube Joint
O±ring Tube Joint Clip
Fuel Suction Plate
±
FUELFUEL 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.
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A81614
Push
A81615
Push
A81616
Tube Joint Clip
Collar
2
1
11±88
±
FUELFUEL 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)
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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
±
FUELFUEL 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 14.2at 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)
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No.1 Fuel Pipe
Fuel Tube Connector
SST
(Clip)
SST (T joint)SST
SST
(Hose)
B12975
11±20
±
FUEL FUEL SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(g) Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration.
SST 09268±41047(95336±08070),09268±45014 (09268±41250, 09268±41200, 09268±41220)
(h) Wipe up any gasoline.
(i) Reconnect the negative (±) battery cable.
(j) Connect the hand±hand tester to the DLC3.
(k) Measure the fuel pressure. Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check the fuel hoses connections, the fuel
pump, the fuel filter and the fuel pressure regulator.
(l) Disconnect the hand±held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle. Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure:147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, the pres-
sure regulator and/or the injectors.
(q) After checking the fuel pressure, disconnect the negative (±) battery cable and carefully remove SST and the fuel
tube connector to prevent gasoline from splashing.
(r) Reconnect the No. 1 fuel pipe (fuel tube connector).
CAUTION:
After taking the precautions, connect the fuel tube con-
necter (quick type).
2. CHECK FUEL PUMP OPERATION AND FUEL LEAK
(a) When using the hand±held tester (1) Connect the hand±held tester to the DLC3.
(2) Turn the ignition switch ON and the hand±held tes-
ter main switch ON.
NOTICE:
Do not start the engine. (3) Select the active test mode on the hand±held tester.
(4) Perform the active test. Check that the fuel pumpoperates and check for fuel leaks.
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110UV±01
Fuel Tube Connector
A50710
Fuel Tube Connector
SST
(Hose)
B12947
SST (Hose)SST
(Clamp)
Vinyl Tube SST (Union)
O±Ring
A51875
11±8
±
FUELFUEL SYSTEM(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1.FUEL INJECTOR ASSY
(a)Inspect injector resistance (1)Using an ohmmeter, measure the resistance be-tween the terminals.
Resistance:
EngineRersistanceCondition
1ZZ±FE13.4 to 14.2
20
C (68
F)
3ZZ±FE13.8 to 15.2
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±0D030)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 SSTs (union and hose) to the injector, andhold the injector and the union with SST (clamp)
SST09268±41047 (95336±08070, 09268±41110, 09268±41300)
(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±5)
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No.1 Fuel Pipe
Fuel Tube Connector
SST
(Clip)
SST (T joint)SST
SST
(Hose)
B12975
11±6
±
FUEL FUEL SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(g) Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration.
SST 09268±41047(95336±08070),09268±45014 (09268±41250, 09268±41200, 09268±41220)
(h) Wipe up any gasoline.
(i) Reconnect the negative (±) battery cable.
(j) Connect the hand±hand tester to the DLC3.
(k) Measure the fuel pressure. Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check the fuel hoses connections, the fuel
pump, the fuel filter and the fuel pressure regulator.
(l) Disconnect the hand±held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle. Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure:147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, the pres-
sure regulator and/or the injectors.
(q) After checking the fuel pressure, disconnect the negative (±) battery cable and carefully remove SST and the fuel
tube connector to prevent gasoline from splashing.
(r) Reconnect the No. 1 fuel pipe (fuel tube connector).
CAUTION:
After taking the precautions, connect the fuel tube con-
necter (quick type).
2. CHECK FUEL PUMP OPERATION AND FUEL LEAK
(a) When using the hand±held tester (1) Connect the hand±held tester to the DLC3.
(2) Turn the ignition switch ON and the hand±held tes-
ter main switch ON.
NOTICE:
Do not start the engine. (3) Select the active test mode on the hand±held tester.
(4) Perform the active test. Check that the fuel pumpoperates and check for fuel leaks.
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No.1 Fuel Pipe
Fuel Tube Connector
SST
(Clip)
SST (T joint)SST
SST
(Hose)
B12975
11±34
±
FUEL FUEL SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(g) Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration.
SST 09268±41047(95336±08070),09268±45014 (09268±41250, 09268±41200, 09268±41220)
(h) Wipe up any gasoline.
(i) Reconnect the negative (±) battery cable.
(j) Connect the hand±hand tester to the DLC3.
(k) Measure the fuel pressure. Fuel pressure:
196 to 588 kPa (2 to 6 kgf/cm
2, 28 to 85 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check the fuel hoses connections, the fuel
pump, the fuel filter and the fuel pressure regulator.
(l) Disconnect the hand±held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle. Fuel pressure:
196 to 588 kPa (2 to 6 kgf/cm
2, 28 to 85 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure:147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, the pres-
sure regulator and/or the injectors.
(q) After checking the fuel pressure, disconnect the negative (±) battery cable and carefully remove SST and the fuel
tube connector to prevent gasoline from splashing.
(r) Reconnect the No. 1 fuel pipe (fuel tube connector).
CAUTION:
After taking the precautions, connect the fuel tube con-
necter (quick type).
2. CHECK FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS
(a) When using the hand±held tester
(1) Connect the hand±held tester to the DLC3.
(2) Turn the ignition switch ON and the hand±held tes-ter main switch ON.
NOTICE:
Do not start the engine.
(3) Select the active test mode on the hand±held tester.
(4) Perform the active test. Check that the fuel pumpoperates and check for fuel leaks.
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A60083
Fuel Pipe
Clamp No.1
AA
B12941
B12944
A82344
Vinyl Bag or plastic Bag
±
FUEL FUEL 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, becareful 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.
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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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110U5±01
A78493
A80060
w/o HID Sensor:
w/ HID Sensor:
(c)
(d)
(c)
±
FUELFUEL TANK ASSY(GASOLINE)
11±93
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
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 COVER, RR FLOOR SERVICE HOLE (See page 11±85)
4.DISCONNECT FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE)
(See page 11±85)
5.DISCONNECT FUEL TANK MAIN TUBE SUB±ASSY (See page 11±85)
6.DISCONNECT FUEL EVAPORATION TUBE SUB±ASSY NO.2 (See page 11±85)
7.REMOVE FUEL SUCTION W/PUMP & GAGE TUBE ASSY (See page 11±85)
SST 09808±14010
8. DRAIN FUEL
9. REMOVE FRONT FLOOR FOOTREST (W/O HID SENSOR)
10.REMOVE FLOOR PANEL BRACE FRONT (See page 15±2)
11. REMOVE EXHAUST PIPE ASSY CENTER(1ZZ±FE/3ZZ±FE ENGINE TYPE)
(a) Using a clip remover, remove the 2 clips. (w/o HID Sensor)
(b) Open the floor carpet. (w/o HID Sensor)
(c) Disconnect the heated oxygen sensor connector.
(d) Remove the grommet. (w/o HID Sensor)
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