fuel pump TOYOTA AVENSIS 2003 Service Owner's Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2003, Model line: AVENSIS, Model: TOYOTA AVENSIS 2003Pages: 2234, PDF Size: 56.95 MB
Page 262 of 2234
A79577
N´m (kgf´cm, ft´lbf): Specified torque
Non±reusable part
Gasket
Gasket Fuel 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
±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FSE)
10±49
AVENSIS REPAIR MANUAL (RM1018E)
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Page 265 of 2234
100FA±01
A79596
A78436
10
10 Upper
Engine
Front
10±52
±
ENGINE CONTROL SYSTEMKNOCK SENSOR(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
2.REMOVE RADIATOR SUPPORT OPENING COVER (See page 18±16)
3.REMOVE ENGINE ROOM COVER SIDE (See page 18±17)
4.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 10±44)
5.DRAIN ENGINE COOLANT (See page 16±31)
6.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±44)
7.REMOVE THROTTLE BODY ASSY (See page 10±44)
8.REMOVE CHARCOAL CANISTER ASSY
9.REMOVE ENGINE COVER BRACKET (See page 11±52)
10.REMOVE FUEL PUMP ASSY (See page 11±52)
11.REMOVE INTAKE MANIFOLD (See page 11±42)
12.REMOVE SURGE TANK STAY NO.1 (See page 11±42)
13.REMOVE INTAKE MANIFOLD INSULATOR NO.2 (See page 11±42) 14.REMOVE KNOCK SENSOR
(a)Remove the nut and the knock sensor.
15.INSTALL KNOCK SENSOR
(a)Install the knock sensor with the nut as shown in the il-lustration.
Torque: 20 Nm (204 kgfcm, 15 ftlbf)
16.INSTALL INTAKE MANIFOLD INSULATOR NO.2 (See page 11±42)
17.INSTALL SURGE TANK STAY NO.1 (See page 11±42)
18.INSTALL INTAKE MANIFOLD (See page 11±42)
19.INSTALL FUEL PUMP ASSY (See page 11±52)
20. INSTALL ENGINE COVER BRACKET
(a) Install the engine cover bracket and the bolt. Torque: 38 N m (388 kgf cm, 28 ftlbf)
21. INSTALL CHARCOAL CANISTER ASSY
22.INSTALL THROTTLE BODY ASSY (See page 10±44)
23.INSTALL AIR CLEANER CAP SUB±ASSY (See page 10±44)
24.ADD ENGINE COOLANT (See page 16±31)
25.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
26. CHECK FOR FUEL LEAKS
27. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
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Page 308 of 2234
110UC±01
A79148
SST
A79143
SST
11±78
±
FUELCOMMON RAIL ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DRAIN ENGINE COOLANT(See page 16±44)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
4.REMOVE RADIATOR RESERVE TANK ASSY(See page 16±50) 5. REMOVE FUEL INLET PIPE SUB±ASSY
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and the injection pump with vinyl tape to prevent dust from
being introduced.
(a) Using SST, remove the fuel inlet pipe from the commonrail.
SST 09023±12700
(b) Using SST, remove the fuel inlet pipe from the injection pump.
SST 09023±12700
6. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts and the 2 upper infection pipe clamps from the intake manifold.
(b) Using SST, remove the injection pipe from the common
rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or plas-
tic bag.
7. REMOVE INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
8. REMOVE INJECTION PIPE SUB±ASSY NO.3 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
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Page 311 of 2234
A79149
30 cm
(11.81 in.)
SST
±
FUELCOMMON RAIL ASSY(1CD±FTV)
11±81
AVENSIS REPAIR MANUAL (RM1018E)
19.INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:
In case of having the common rail replaced, must re-
place fuel inlet pipe, too.
When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a)Temporarily install the fuel inlet pipe.
(b)Using SST, tighten the nut of the fuel inlet pipe to the com-
mon rail side.
SST09023±12700
Torque:
42 Nm (428 kgfcm, 31 ftlbf) for a used pipe using SST
46 Nm (469 kgfcm, 34 ftlbf) for a used pipe not using
SST
31 N m (316 kgfcm, 23 ftlbf) for a new pipe using SST
34 Nm (347 kgf cm, 25 ftlbf) for a new pipe not using
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
(c)Using SST, tighten the nut of the fuel inlet pipe to the injec-
tion pump side.
SST09023±12700
Torque:
42 Nm (428 kgfcm, 31 ftlbf) for a used pipe using SST
46 Nm (469 kgfcm, 34 ftlbf) for a used pipe not using
SST
31 N m (316 kgfcm, 23 ftlbf) for a new pipe using SST
34 Nm (347 kgf cm, 25 ftlbf) for a new pipe not using
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
20.INSTALL RADIATOR RESERVE TANK ASSY(See page 16±50)
21. INSTALL ENGINE COVER NO.1 Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
22.ADD ENGINE COOLANT(See page 16±44)
23.CHECK FOR ENGINE COOLANT LEAKS(See page 16±37)
24.CHECK FOR FUEL LEAKS(See page 11±60)
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Page 321 of 2234
A79577
N´m (kgf´cm, ft´lbf): Specified torque
Non±reusable part
Gasket
Gasket Fuel 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
±
FUEL FUEL INJECTOR ASSY (1AZ±FSE)
11±39
AVENSIS REPAIR MANUAL (RM1018E)
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Page 330 of 2234
110TA±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±assy VSV
Connector
Fuel Vapor Feed Hose
Clip
Engine Room Cover Side
Radiator Support Opening Cover
Clip Retainer
x2
x4
1.5 (15, 13 in.lbf)
±
FUEL FUEL PUMP ASSY (1AZ±FSE)
11±49
AVENSIS REPAIR MANUAL (RM1018E)
FUEL PUMP ASSY (1AZ±FSE)
COMPONENTS
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Page 331 of 2234
A78508 Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque Throttle Body Assy
Throttle 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±50
±
FUEL FUEL PUMP ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
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Page 332 of 2234
A79577
N´m (kgf´cm, ft´lbf): Specified torque
Non±reusable part
Gasket
Gasket Fuel 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
±
FUEL FUEL PUMP ASSY (1AZ±FSE)
11±51
AVENSIS REPAIR MANUAL (RM1018E)
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Page 333 of 2234
110TB±01
A79569
A79570
SST
A79571
A79572
11±52
±
FUELFUEL PUMP ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
2.REMOVE RADIATOR SUPPORT OPENING COVER (See page 18±16)
3.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 10±44)
4.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±44) 5.REMOVE ENGINE COVER BRACKET
(a)Remove the bolt and the engine cover bracket.
6.REMOVE FUEL PRESSURE PULSATION DAMPERASSY
(a)Disconnect the fuel tube sub±assy. (See page 11±30)
(b) Using SST, remove the fuel pressure pulsation damper assy, the fuel tube sub±assy and the 2 gasket.
SST 09617±24011
7. REMOVE FUEL PIPE SUB±ASSY NO.1
(a) Remove the fuel hose.
(b) Clamp the union bolt on the fuel pump assy with a 21 mm wrench and remove the fuel pipe sub±assy No. 1 from the
fuel pump assy using a 19 mm union±nut wrench.
NOTICE:
Do not loosen the union bolt on the fuel pump assy. If it be-
come loose, replace the fuel pump assy with new fuel
pump assy.
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Page 334 of 2234
A79573
A79574
A79834
±
FUEL FUEL PUMP ASSY (1AZ±FSE)
11±53
AVENSIS REPAIR MANUAL (RM1018E)
(c) Remove the 2 bolts first, then remove the fuel pipe sub±
assy No. 1 from 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 removing the
fuel pipe No.1.
8. REMOVE FUEL PUMP ASSY
(a) Disconnect the fuel pump assy connector.
(b) Remove the 2 nuts and the fuel pump assy.
(c) Remove the fuel pump insulator.
9. INSTALL FUEL PUMP ASSY
(a) Turn the crankshaft and set the camshaft to the position
where the oil port of the camshaft can be seen from the
fuel pump mounting hole.
(b) From the fuel pump mounting hole of the cylinder head,
pour 35 to 45cc (2.14 to 2.75 cu in) engine oil into the cyl-
inder head.
(c) For more smooth rotation, apply engine oil on the cam lobe which can be seen from the fuel pump mounting hole
using fingers.
(d) Set a new fuel pump insulator and fuel pump assy with the 2 nuts.
Torque: 25 N m (255 kgf cm, 18 ftlbf)
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