fuel TOYOTA AVENSIS 2003 Service Owner's Guide

031E1±02
03±8
±
SERVICE SPECIFICATIONS FUEL
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Fuel delivery pipe sub±assy x Cylinder head sub±assy Bolt A
Bolt B19
9.0194 9214
80 in.
lbf
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Fuel delivery pipe sub±assy x Cylinder head sub±assy2020415
Fuel pressure pulsation damper assy x Fuel delivery pipe sub±assy9.09280 in.
lbf
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Cylinder head cover x Fuel pump assy2525518
Fuel pipe sub±assy No.1 x Fuel delivery pipe sub±assy9.09280 in.
lbf
Fuel pipe sub±assy No.1 x Fuel pump assy3030622
Fuel pressure pulsation damper assy x Fuel pump assy3333124
Engine cover bracket x Cylinder head3838828
Engine cover sub±assy No.1 x Cylinder head cover7.07162 in.
lbf
Nozzle holder clamp x Cylinder head131279
Fuel delivery pipe sub±assy x Cylinder head1919414
Surge tank stay No.1 x Cylinder block2121015
Intake manifold x Cylinder head Stud bolt
BoltNut9.5
30
3097
306
30684 in.
lbf
22
22
GASOLINE:
Part TightenedN
mkgf
cmft
lbf
Fuel tank band sub±assy No. 1 LH x Body4040029
Fuel tank band sub±assy No. 1 RH x Body4040029
Parking brake cable assy No. 3 x Body5.05144 in.
lbf
Parking brake cable assy No. 2 x Body5.05144 in.
lbf
Fuel tank protector No. 1 x Body5.45447 in.
lbf
Fuel tank protector No. 1 x Fuel tank band sub±assy No. 1 RH5.45447 in.
lbf
Exhaust pipe assy front x Exhaust manifold (1ZZ±FE/3ZZ±FE)4344033
Exhaust pipe assy front x Exhaust pipe assy tail (1ZZ±FE/3ZZ±FE)\
4344033
Exhaust pipe assy center x Exhaust pipe assy front (1AZ±FE/1AZ±FS\
E)4344033
Exhaust pipe assy center x Exhaust pipe assy tail (1AZ±FE/1AZ±FSE\
)4344033
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Nozzle holder clamp x Cylinder head sub±assy2626519
Nozzle leakage pipe assy x Injector assy Hollow screw
Union bolt18
22184
22413
16
Nozzle leakage pipe No. 2 x Cylinder head sub±assy Hollow screw Bolt21
8.8214 9016
79 in.
lbf
Injection pipe sub±assy No. 1 ± No. 4 x Injector assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Injection pipe sub±assy No. 1 ± No. 4 x Common rail assy Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
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±
SERVICE SPECIFICATIONS FUEL
03±9
AVENSIS REPAIR MANUAL (RM1018E)Part Tightened
ft
lbf
kgf
cm
N
m
Injection pipe clamp No. 2 x Intake manifold5.05144 in.
lbf
Fuel inlet pipe sub±assy x Common rail assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe sub±assy x Injection pump assy Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Air cleaner case x Body7.07162 in.
lbf
Air cleaner case x Transverse engine engine mounting bracket7.07162 in.
lbf
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Vacuum reservoir sub±assy x Cowl top panel outer8.38574 in.
lbf
Injection pump assy x Water pump assy2121015
Injection pump drive pulley x Injection pump assy6465047
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
Common rail assy x Cylinder head sub±assy4343832
Transverse engine engine mounting bracket x Water pump assy6465047
Transverse engine engine mounting bracket x Cylinder block sub±assy3737527
Idler pulley sub±assy x V±ribbed belt tensioner assy4040830
Battery clamp sub±assy x Body5.05144 in.
lbf
Front wheel1031,05076
Fuel filter assy x Fuel filter support1817813
DIESEL:
Part TightenedN
mkgf
cmft
lbf
Fuel tank band sub±assy x Body4040029
Parking brake cable assy x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Fuel tank band sub±assy No. 15.45548 in.
lbf
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031FW±01
03±44
±
SERVICE SPECIFICATIONS PARKING BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Wheel nut1031,05076
Parking brake lock nut5.05144 in.
lbf
Parking brake lever sub±assy x Body131279
Front floor heat insulator No.2 x Body5.55649 in.
lbf
Front floor heat insulator No.1 x Body5.55649 in.
lbf
Exhaust pipe installation bolt4344032
Front floor panel brace x Body3030221
Fuel tank protector No.1 x Body5.55649 in.
lbf
Parking brake cable assy No.3 x Fram5.05144 in.
lbf
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3020
10
5
3
02040
0.1 1
0.3 0.2
0.5 2
60 80 100
±20
(±4) (104) (140) (176)
(32) (68) (212)
Z17274
Ohmmeter
Acceptable
Temperature
C (
F)
Resistance k

THF E2
A30331
30
20
10




0.5
0.3
0.2
0.1
±20

20 40 60
80 100
F14741(±4) (104) (140) (176)
(32) (68) (212)
A56276
Temperature
C (
F)
Resistance k

±
ENGINE CONTROL SYSTEM ECD SYSTEM (1CD±FTV)
10±57
AVENSIS REPAIR MANUAL (RM1018E)
3. INSPECT DIESEL ENGINE ENGINE COOLANT
TEMPERATURE SENSOR
(a) Resistance inspection.
(1) Using an ohmmeter, measure the resistance be-tween each terminal.
Resistance:
Approx. 20
C (68
F) 2.32 to 2.59 k

Approx. 80
C (176
F) 0.310 to 0.326 k

NOTICE:
In case of checking the water temperature sensor in the wa-
ter, be careful not to allow water to go into the terminals,
and after checking, wipe out the sensor.
4. INSPECT INJECTION OR SUPPLY PUMP ASSY
(a) Resistance inspection. (Fuel temperature sensor) (1) Using an ohmmeter, measure the resistance be-tween each terminal.
Resistance:
Approx. 20
C (68
F) 2.21 to 2.69 k

Approx. 80
C (176
F) 0.287 to 0.349 k

5. INSPECT DIESEL TURBO INLET AIR TENPERATURE SENSOR
(a) Resistance inspection. (1) Using an ohmmeter, measure the resistance be-
tween each terminal.
Resistance:
Approx. 20
C (68
F) 2.21 to 2.65 k

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100FR±01
A79186
±
ENGINE CONTROL SYSTEMECM
10±65
AVENSIS REPAIR MANUAL (RM1018E)
ECM
REPLACEMENT
HINT:
1CD±FTV Engine Type:
Each injector assembly has a characteristic fuel injecting behavior. The ECM stores compensation codes
which are used to optimize fuel injection for the injectors. When replacing t\
he ECM, the compensation codes
must be set to the new ECM.
1.REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71±11)
2.REMOVE ECM
(a)Disconnect the 4 ECM connectors (1ZZ±FE, 3ZZ±FE,1AZ±FE, 1CD±FTV).
(b)Disconnect the 5 ECM connectors (1AZ±FSE).
(c)Disconnect the wire harness clamp.
(d)Remove the bolt and screw, then remove the ECM.
(e)Remove the 2 screws and the ECM bracket No. 1 from the ECM.
(f)Remove the 2 screws and the ECM bracket No. 2 from the ECM.
3.INSTALL ECM Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
4.INSTALL GLOVE COMPARTMENT DOOR ASSY (See page 71±11)
5.REGISTRATION OF INJECTOR COMPENSATION CODE (1CD±FTV ENGINE TYPE) (See page 05±528)
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100FK±01
A77870
Mass Air Flow
Meter Connector
N´m (kgf´cm, ft´lbf) : Specified torqueEngine Cover Sub±assy
No. 1
7.0 (71, 62 in.

lbf)
Fuel Vapor Feed Hose
No. 2
Air Cleaner Cap
Sub±assy VSV
Connector
Fuel Vapor Feed Hose
Clip
Engine Room Cover Side
Radiator Support Opening Cover
Clip Retainer
x2
x4
10±30
±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
KNOCK SENSOR (1AZ±FE)
COMPONENTS
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A78452
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque Accelerator
Control Cable Assy

Throttle Body
Gasket
Water By±pass Hose No. 2 Water By±pass Hose Fuel Tube Sub±assy
Fuel Pipe Support
Throttle Position Sensor
Connector
ISC Valve Connector
13 (129, 9)
30 (306, 22)
Throttle Body Assy
±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FE)
10±31
AVENSIS REPAIR MANUAL (RM1018E)
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A78453
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
20 (204, 15)
Fuel Injector
Connector
EFI Fuel Pipe Clamp
Fuel Tube Sub±assy
Injector Vibration Insulator Delivery Pipe No. 1
Spacer
Fuel Delivery Pipe Sub±assy
Ventilation Hose No. 2
10±32
±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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A77916
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
30 (306, 22)
Heater Inlet Water Hose
Knock Sensor
ConnectorKnock Sensor
20 (204, 15)
Intake Manifold Insulator No. 1


Intake Manifold
to Head Gasket No. 1
Intake Manifold
LHD Steering Position Type,
Leaded Gasoline:
Variable Resister
5.0 (51, 44 in.
lbf)
Charcoal Canister Assy
Variable Resister Connector
Charcoal Canister
Outlet Hose No. 1
Fuel Hose
x5
±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FE)
10±33
AVENSIS REPAIR MANUAL (RM1018E)
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100FL±01
A77917
A77918
(a)
(b)
A77919
10±34
±
ENGINE CONTROL SYSTEMKNOCK SENSOR(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE ENGINE ROOM COVER SIDE (See page 10±26)
3.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±26)
4.ENGINE COOLANT (See page 16±19)
5.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
6.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±26)
7.SEPARATE ACCELERATOR CONTROL CABLE ASSY (See page 10±26)
8.REMOVE THROTTLE BODY ASSY (See page 10±26)
9.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±26) SST 09268±21010
10.REMOVE FUEL DELIVERY PIPE SUB±ASSY (See page 11±26)
11. REMOVE VARIABLE RESISTOR (LHD STEERINGPOSITION TYPE, LEADED GASOLINE)
(a) Disconnect the variable resistor connector.
(b) Remove the bolt, and then remove the variable resistor.
12. REMOVE CHARCOAL CANISTER ASSY
(a) Disconnect the charcoal canister outlet hose No. 1.
(b) Disconnect the fuel hose.
(c) Pull up and remove the charcoal canister.
13. DISCONNECT HEATER INLET WATER HOSE
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