TOYOTA AVENSIS 2003 Service Repair Manual

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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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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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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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 ft
lbf)
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A79575
Fuel Injector
Back±up Ring No. 1
Fuel Injector
Back±up Ring No. 2
O±ring
Fuel injector
Back±up Ring No. 3
A79576
A79570
SST
11±54
±
FUEL FUEL PUMP ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL FUEL PIPE SUB±ASSY NO.1
(a) Attach a new O±ring, fuel injector back±up ring No. 1, No. 2 and No. 3 to the fuel pipe sub±assy No.1.
(b) Apply a small amount of fuel on the O±ring and install the fuel pipe sub±assy No. 1 to the fuel pump assy and 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 installing the fuel
pipe No.1.
(c) Tighten the nut by hand to attach the fuel pipe sub±assy No. 1 to the fuel pump assy.
(d) In order to secure the fuel pipe sub±assy No. 1 to the fuel delivery pipe sub±assy, tighten the 2 bolts to the specified
torque.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
(e) Clamp the union bolt on the fuel pump assy with a 21 mm wrench and tighten the nut with the specified torque to se-
cure the fuel pipe sub±assy No. 1 to the fuel pump assy
using a 19 mm union±nut wrench.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
11. INSTALL FUEL PRESSURE PULSATION DAMPER ASSY
(a) Install the fuel pulsation damper assy to the fuel pump assy after fitting new 2 gaskets and fuel tube sub±assy
between those assys.
(b) Using SST, install the fuel pressure pulsation damper assy to the fuel pump assy.
SST 09617±24011
Torque: 33 N
m (331 kgf
cm, 24 ft
lbf)
(c) Connect the fuel tube sub±assy.
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±
FUELFUEL PUMP ASSY(1AZ±FSE)
11±55
AVENSIS REPAIR MANUAL (RM1018E)
12.INSTALL ENGINE COVER BRACKET
(a)Install the engine cover bracket with the bolt.
Torque: 38 N
m (388 kgf
cm, 28 ft
lbf)
13.INSTALL AIR CLEANER CAP SUB±ASSY (See page 10±44)
14. CHECK FOR FUEL LEAKS
15. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
16. INSTALL RADIATOR SUPPORT OPENING COVER
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110U3±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
11±84
±
FUEL FUEL PUMP ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
FUEL PUMP ASSY (GASOLINE)
COMPONENTS
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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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A78444
2
1
Pinch1
Pinch
A75650
Tube ConnectorPipe
O±ring
Nylon Tube
A78445
2
Pinch
Pinch1
1
A65059
Nylon Tube
O±ringFuel Tube
Connector Clip
Fuel Tube
Connector Pipe
A78446
SST
Rib
11±86
±
FUEL FUEL PUMP ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
5. DISCONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a) Pinch the tube connector and 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 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.
6. DISCONNECT FUEL EVAPORATION TUBE SUB±ASSY NO.2
(a) Pinch the fuel tube connector clip and pull out the fuel evaporation 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 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.
7. REMOVE FUEL SUCTION W/PUMP & GAGE TUBE ASSY
(a) Using SST, loosen the fuel pump gauge retainer.
SST 09808±14010
NOTICE:
Do not use other tools in this operation. Damage to the fuel
pump gauge retainer and the fuel tank may result.
HINT:
A rib on the fuel pump gauge retainer can be fitted into a tip of
the SST.
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A78447
A78448
Triangle Mark
Matchmark
A78446
SST
Rib
A78449
Arrow Mark
±
FUEL FUEL PUMP ASSY (GASOLINE)
11±87
AVENSIS REPAIR MANUAL (RM1018E)
(b) Remove the fuel pump gauge retainer.
(c) Remove the fuel suction w/ pump & gage tube.
NOTICE:
Be careful that the arm of the fuel sender gage should not
be bent.
(d) Remove the gasket from the tank.
8. INSTALL FUEL SUCTION W/PUMP & GAGE TUBE
ASSY
(a) Install a new gasket to the fuel tank.
(b) Install the fuel suction w/ pump & gage tube.
NOTICE:
Be careful that the arm of the fuel sender gage should not
be bent.
(c) Align the triangle mark of the fuel suction w/ pump & gage tube with the matchmark location the fuel tank.
(d) Temporarily install the fuel pump gauge retainer.
(e) Using SST, tighten the fuel pump gauge retainer until the arrow mark is aligned with the center mark on the fuel
tank.
SST 09808±14010
NOTICE:
Do not use other tools in this operation. Damage to the fuel
pump gauge retainer and the fuel tank may result.
HINT:
A rib on the fuel pump gauge retainer can be fitted into a tip of
the SST.
(f) Check that the arrow mark and center mark are aligned as shown in the illustration.
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