TOYOTA AVENSIS 2003 Service Repair Manual

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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A79597
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket

Gasket
38 (388, 28)
21 (210, 15)
9.5 (97, 84 in.
lbf)
30 (306, 22)
9.8 (100, 7)
30 (306, 22)
30 (306, 22)
Union to Connector
Tube Hose
Vacuum Hose
Intake Manifold
Insulator No. 1
Intake Air Control Valve Assy
Intake Manifold Insulator No. 2
Surge Tank
Stay No. 1
Engine Cover Bracket Charcoal Canister Assy
Intake Manifold
x2
11±40
±
FUEL FUEL INJECTOR ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
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A79598
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Fuel Injector Seal

Gasket
13 (127, 9)
19 (194, 14)

O±ring

E±ring

Fuel Injector
Back±up Ring No. 3

Fuel Injector
Back±up Ring No. 2


Fuel Injector
Back±up Ring No. 1
Injector Assy
Fuel Delivery
Pipe Sub±assy
Nozzle Holder Clamp
x5
±
FUEL FUEL INJECTOR ASSY (1AZ±FSE)
11±41
AVENSIS REPAIR MANUAL (RM1018E)
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110TY±01
A78470

Fuel Injector O±Ring

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
7.0 (71, 62 in.´lbf)
Ventilation Hose
Fuel Injector Connector
No. 1 Spacer


Injector Vibration
Insulator Fuel Delivery Pipe
Sub±assy
Fuel Tube Sub±assy
Fuel Pipe Clamp No. 2
Cylinder Head Cover No. 2


Fuel Injector O±Ring

Fuel Injector Grommet
Fuel Injector Assy
Fuel Injector Assy
1ZZ±FE:
Clip
3ZZ±FE:
19 (189, 14)
9.0 (91, 80 in.´lbf)
11±10
±
FUEL FUEL INJECTOR ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
FUEL INJECTOR ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
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110TZ±01
A78471
Retainer
(at 4 places)
Insert
SST
Turn
Fuel Pipe
Clamp
A76220
O±ring
Nylon Tube HousingPipe
Retainer
A78472
±
FUELFUEL INJECTOR ASSY(1ZZ±FE/3ZZ±FE)
11±11
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±1)
2.REMOVE CYLINDER HEAD COVER NO.2 (See page 10±9)
3. SEPARATE FUEL TUBE SUB±ASSY
(a) Remove the fuel pipe clamp.
(b) Using SST, disconnect the fuel tube.SST 09268±21010
(1) Assemble SST to the connection of the fuel tube asshown in the illustration.
(2) Turn SST, align the retainers inside the connector
with SST into the connector.
(3) Push in the SST and the connector together to- wards the fuel tube assembly.
NOTICE:

Check if there is any dirt or mud on the pipe and
around the connector before disconnecting them and
remove the dirt as necessary.

Do not bent and twist the nylon tube.

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

Prevent the disconnected pipe and connector from
being damaged and foreign objects from being
introduced, cover with a vinyl or plastic bag.
4. REMOVE FUEL DELIVERY PIPE SUB±ASSY
(a) Disconnect the ventilation hose.
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A78473
(a)(a)
(a)
(a)
(b)
(b)
(b)
A78480
A78475
Delivery Pipe No. 1 spacer
Insulator
A78476
11±12
±
FUEL FUEL INJECTOR ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Disconnect the 4 fuel injector connectors.
(c) Remove the 3 wire harness clamps.
(d) Remove the 3 bolts, and then remove the fuel delivery pipe together with the 4 fuel injectors.
NOTICE:
Be careful not to drop the fuel injectors when removing the
fuel delivery pipe.
(e) Remove the 2 delivery pipe No. 1 spacers and the 4 insu- lators from the cylinder head.
5. REMOVE FUEL INJECTOR ASSY
(a) Pull out the 4 fuel injectors from the fuel delivery pipe.
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A78477
New O±ring
1ZZ±FE:
A78478
New O±ring
3ZZ±FE:
New Grommet
A78479
Turn
Push
A78474
Turn
A
A
B
±
FUEL FUEL INJECTOR ASSY (1ZZ±FE/3ZZ±FE)
11±13
AVENSIS REPAIR MANUAL (RM1018E)
6. INSTALL FUEL INJECTOR ASSY
(a) Install new grommets to each fuel injector. (3ZZ±FE)
(b) Apply a light coat of spindle oil or gasoline to new O±rings,
and install them to each fuel injector.
(c) Apply a light coat of spindle oil or gasoline on the place where the fuel delivery pipe contacts the O±ring.
(d) Push the fuel injector while twisting it back and forth to install it to the fuel delivery pipe.
NOTICE:

Be careful not to twist the O±ring.

After installing the fuel injectors, check that they turn
smoothly. If not, reinstall it with a new O±ring.
7. INSTALL FUEL DELIVERY PIPE SUB±ASSY
(a) Instal 4 new insulators and the 2 delivery pipe No. 1 spacers to the cylinder head.
(b) Place the fuel delivery pipe and 4 fuel injectors together
to the cylinder head.
NOTICE:
Be careful not to drop the fuel injectors when installing the
fuel delivery pipe.
(c) Temporarily install 3 bolts which are used to secure the fuel delivery pipe to the cylinder head.
(d) Check that the fuel injectors rotate smoothly.
If fuel injectors do not rotate smoothly, the probable cause is in-
correct installation of O±ring. Replace with the O±ring.
(e) Tighten the 3 bolts. Torque:
19 N
m (194 kgf
cm, 14 ft
lbf) for bolt A
9.0 N
m (92 kgf
cm, 80 in.
lbf) for bolt B
(f) Install the 3 wire harness clamps.
(g) Connect the 4 fuel injector connectors.
(h) Connect the ventilation hose.
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A81613
Fuel Pipe
Clamp
Push
11±14
±
FUELFUEL INJECTOR ASSY(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
8.CONNECT FUEL TUBE SUB±ASSY
(a)Push in the 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 connector and the pipe
are securely connected by pulling on them.
(b)Install the fuel pipe clamp.
9.CHECK FOR FUEL LEAKS (See page 11±5)
10.INSTALL CYLINDER HEAD COVER NO.2 (See page 10±9)
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110U2±01
A77915
±
FUELFUEL PRESSURE PULSATION DAMPER
ASSY(1AZ±FE)11±29
AVENSIS REPAIR MANUAL (RM1018E)
FUEL PRESSURE PULSATION DAMPER ASSY(1AZ±FE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
3.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±26)
4.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±26)
SST09268±21010
5.REMOVE FUEL PRESSURE PULSATION DAMPERASSY
(a)Remove the 2 bolts, and then remove the fuel pressure pulsation damper.
6.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY
(a)Apply a light coat of spindle oil or gasoline to a new O±ring, and instal\
l it to the fuel pressure pulsation damper.
(b)Install the fuel pressure pulsation damper with the 2 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
7.CONNECT FUEL TUBE SUB±ASSY (See page 11±26)
8. INSTALL AIR CLEANER CAP SUB±ASSY
9.CHECK FOR FUEL LEAKS (See page 11±19)
10.INSTALL ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
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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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