TOYOTA AVENSIS 2003 Service Repair Manual

A77881
Fuel Tank AssyFuel Hose No. 1
Fuel Tank
to Filler Pipe Hose
Fuel Tank Band Sub±assy
No. 1
Fuel Tank Band Sub±assy
No. 1 LH
Fuel Tank Protector
No. 1
Parking Brake Cable Assy
No. 2
Parking Brake Cable Assy
No. 3
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
5.4 (54, 47 in.
lbf)x4
40 (400, 29)
40 (400, 29)
N´m (kgf´cm, ft´lbf) : Specified torque
±
FUEL FUEL TANK ASSY (GASOLINE)
11±91
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

A77882
1AZ±FSE:
Fuel Tank Return TubeFuel Evaporation Tube Sub±assy
No. 2
Fuel Tank Main Tube Sub±assy
Fuel Tank Assy
11±92
±
FUEL FUEL TANK ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

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)
http://vnx.su

A78518
(e)(e)
(e)
(e)
(f)
(f)
11±94
±
FUEL FUEL TANK ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
(e) Remove the 4 bolts and 4 compression springs.
(f) Remove the exhaust pipe front from the 2 exhaust pipe supports.
(g) Remove each gasket from the exhaust manifold and the exhaust pipe front.
http://vnx.su

A78519
(a)
(b)
(a)(b)
(a)
(a)
A77883
A77884
±
FUEL FUEL TANK ASSY (GASOLINE)
11±95
AVENSIS REPAIR MANUAL (RM1018E)
12. REMOVE EXHAUST PIPE ASSY CENTER
(1AZ±FE/1AZ±FSE ENGINE TYPE)
(a) Remove the 4 bolts and 2 compression springs.
(b) Remove the exhaust pipe center and the gasket from the
2 exhaust pipe supports.
(c) Remove the gasket from the exhaust pipe center.
13. REMOVE FUEL TANK PROTECTOR NO.1
(a) Remove the 4 bolts, and then remove the fuel tank pro- tector.
14. REMOVE PARKING BRAKE CABLE ASSY NO.2
(a) Remove the 2 set bolts of the parking brake cable.
http://vnx.su

A77885
A77886
A77887
A78450
11±96
±
FUEL FUEL TANK ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
15. REMOVE PARKING BRAKE CABLE ASSY NO.3
(a) Remove the 2 set bolts of the parking brake cable.
16. DISCONNECT BREATHER TUBE FUEL HOSE
(a) Loosen the hose clamp and disconnect the fuel tank breather hose.
17. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
(a) Loosen the hose clamp and disconnect the fuel tank to fill- er pipe hose.
18. DISCONNECT FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE)
http://vnx.su

A77888
1
2
3
Retainer
Pinch
Pinch
2
A63387
RetainerPipe
O±ring
Fuel Tube Connector
A77889
2
Pinch1
Pinch1
A60576
Nylon Tube
Pipe
O±ring Fuel Tube
Connector Clip
Fuel Tube
Connector
A77890
±
FUEL FUEL TANK ASSY (GASOLINE)
11±97
AVENSIS REPAIR MANUAL (RM1018E)
19. 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 plastic bag.

When the pipe and connector are stuck, push and pull
the connector to release. Pull out the connector from
the pipe.
20. 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 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 plastic bag.

When the pipe and connector are stuck, push and pull
the connector to release. Pull out the connector from
the pipe.
21. REMOVE FUEL TANK ASSY
(a) Set a transmission jack to the fuel tank.
(b) Remove the 4 bolts and the 2 fuel tank bands, and then remove the fuel tank.
http://vnx.su

A77894
A77891
A77892
A77893
UpperFuel Tank
Rear
Hose Clamp
A81617
Push
11±98
±
FUEL FUEL TANK ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
22. REMOVE FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE)
(a) Unfasten the 5 claws and remove the fuel tank return tube
from the fuel tank.
23. REMOVE FUEL EVAPORATION TUBE SUB±ASSY NO.2
(a) Unfasten the 4 claws and remove the fuel evaporation tube from the fuel tank.
24. REMOVE FUEL TANK MAIN TUBE SUB±ASSY
(a) Unfasten the 4 claws and remove the fuel tank main tube from the fuel tank.
25. INSTALL FUEL TANK MAIN TUBE SUB±ASSY
26. INSTALL FUEL EVAPORATION TUBE SUB±ASSY NO.2
(a) Install the hose clamp as shown in the illustration.
27. INSTALL FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE)
28. INSTALL FUEL TANK ASSY Torque: 40 N
m (400 kgf
cm, 29 ft
lbf)
29. 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.
http://vnx.su

A81618
Push
2
1Retainer
A77857
A78440
New Gasket
A77857
±
FUEL FUEL TANK ASSY (GASOLINE)
11±99
AVENSIS REPAIR MANUAL (RM1018E)
30. CONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a) Push in the fuel tube connector to the pipe until it makes
ºclickº sound, and then push up the retainer to the claws
lock.
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.
31. CONNECT FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE)
32. CONNECT FUEL TANK TO FILLER PIPE HOSE
33. CONNECT BREATHER TUBE FUEL HOSE
34. INSTALL PARKING BRAKE CABLE ASSY NO.3
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
35. INSTALL PARKING BRAKE CABLE ASSY NO.2
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
36. INSTALL FUEL TANK PROTECTOR NO.1 Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
37. INSTALL EXHAUST PIPE ASSY CENTER (1ZZ±FE/3ZZ±FE ENGINE TYPE)
(a) Compression spring inspection (1) Using vernier calipers, measure the free length ofthe compression spring.
Minimum length:
41.5 mm (1.634 in.) for front x manifold
38.5 mm (1.516 in.) for front x tail
If the free length is less than minimum, replace the compression
spring.
(b) Install each new gasket to the exhaust manifold and the
exhaust pipe front as shown in the illustration.
(c) Install the exhaust pipe front to the 2 exhaust pipe sup- ports
(d) Tighten the 4 compression springs and 4 bolts. Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
(e) Install the grommet. (w/o HID Sensor)
(f) Connect the heated oxygen sensor connector.
(g) Install the floor carpet with the 2 clips. (w/o HID Sensor)
38. INSTALL EXHAUST PIPE ASSY CENTER (1AZ±FE/1AZ±FSE ENGINE TYPE)
(a) Compression spring inspection
(1) Using vernier calipers, measure the free length ofthe compression spring.
Minimum length: 38.5 mm (1.516 in.)
If the free length is less than minimum, replace the compression
spring.
http://vnx.su

A78440
New Gasket
11±100
±
FUELFUEL TANK ASSY(GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install a new gasket to the the exhaust pipe center (ex- haust pipe tail side) as shown in the illustration.
(c)Install a new gasket (exhaust pipe front side) and the ex-
haust pipe center to the 2 exhaust pipe supports.
(d)Tighten the 2 compression springs and 4 bolts. Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
39.ADD FUEL
40.INSTALL FUEL SUCTION W/PUMP & GAGE TUBE ASSY (See page 11±85) SST 09808±14010
41.CONNECT FUEL EVAPORATION TUBE SUB±ASSY NO.2 (See page 11±85)
42.CONNECT FUEL TANK MAIN TUBE SUB±ASSY (See page 11±85)
43.CONNECT FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE) (See page 11±85)
44. CHECK FOR FUEL LEAKS
HINT:

1ZZ±FE/3ZZ±FE: 11±5

1AZ±FE: 11±19

1AZ±FSE: 11±33
45. CHECK FOR EXHAUST GAS LEAKS
46.INSTALL FLOOR PANEL BRACE FRONT (See page 15±2)
47. INSTALL REAR FLOOR SERVICE HOLE COVER
48.INSTALL REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 72±32)
49. INSTALL FRONT FLOOR FOOTREST (W/O HID SENSOR)
http://vnx.su