fuel cap TOYOTA AVENSIS 2003 Service Owner's Guide

110U1±01
A77908
Retainer
(at 4 places)
Insert
SST
Turn
Fuel Pipe
Clamp
A76220
O±ring
Nylon Tube HousingPipe
Retainer
A77909
11±26
±
FUELFUEL INJECTOR ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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
(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.
5. REMOVE FUEL DELIVERY PIPE SUB±ASSY
(a) Disconnect the ventilation hose.
http://vnx.su

A77913
Turn
Push
A77914
Turn
A81621
Fuel Pipe
Clamp
Push
11±28
±
FUELFUEL INJECTOR ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Apply a light coat of spindle oil or gasoline on the place where a fuel delivery pipe contacts the O±ring.
(c)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.
8.INSTALL FUEL DELIVERY PIPE SUB±ASSY
(a)Install 4 new insulators and the 2 delivery pipe No. 1 spacers to the cylinder head.
(b)Place the fuel delivery pipe and the 4 fuel injectors togeth- er to the cylinder head.
NOTICE:
Be careful not to drop the fuel injectors when installing the
fuel delivery pipe.
(c)Temporarily install 2 bolts which are used to secure the fuel delivery pipe to the cylinder head.
(d)Check that the fuel injectors rotate smoothly.
If the fuel injectors do not rotate smoothly, the probable cause
is incorrect installation of O±ring. Replace with the O±ring.
(e)Tighten the 2 bolts. Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(f)Connect the 4 fuel injector connectors.
(g)Install the 2 wire harness clamps.
(h)Connect the ventilation hose.
9.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.
10.INSTALL AIR CLEANER CAP SUB±ASSY
11.CHECK FOR FUEL LEAKS (See page 11±19)
12.INSTALL ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
http://vnx.su

110TC±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 INJECTOR ASSY (1AZ±FSE)
11±37
AVENSIS REPAIR MANUAL (RM1018E)
FUEL INJECTOR ASSY (1AZ±FSE)
COMPONENTS
http://vnx.su

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)
http://vnx.su

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
http://vnx.su

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.
http://vnx.su

±
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
http://vnx.su

110U9±01
A79435
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
7.0 (71, 62 in.
lbf)
N´m (kgf´cm, ft´lbf)
: Specified torque
Radiator Hose Outlet
Clip
Engine Room Cover Side
Clip
Retainer
Radiator Support
Opening Cover
8.0 (82, 71 in.
lbf)
5.0 (51, 44 in.
lbf)
V (Cooler Compressor
to Crankshaft Pulley)
Belt No. 1
Injector Driver
72 (734, 53)
52 (530, 38)52 (530, 38)
Engine Cover No. 1
Engine Mounting Insulator Sub±assy RH
39 (398, 29)
Power Steering
Idle Pulley Bracket
52 (530, 38)
Clip
Engine Under Cover RH
Engine Under Cover Sub±assy No. 1
Clip
Radiator Reserve Tank Assy
6.0 (61, 53 in.
lbf)
11±66
±
FUEL INJECTION OR SUPPLY PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
INJECTION OR SUPPLY PUMP ASSY (1CD±FTV)
COMPONENTS
http://vnx.su

110U7±01
A79434
Radiator Support Opening Cover
Engine Cover No. 1
Vacuum Reservoir Sub±assy
Union To Connector Tube Hose
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
N´m (kgf´cm, ft´lbf) : Specified torque
8.0 (82, 71 in.
lbf)
8.3 (85, 73 in.
lbf)
7.0 (71, 62 in.
lbf)
Clip
Retainer
25 (255, 18)
Air Tube No. 1
25 (255, 18)
11±58
±
FUEL INJECTOR ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
INJECTOR ASSY (1CD±FTV)
COMPONENTS
http://vnx.su

110U8±01
A79143
SST
11±60
±
FUELINJECTOR ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
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 injector assembly, a compensa-
tion code for the new injector assembly must be set to the ECM.
1.REMOVE VACUUM RESERVOIR SUB±ASSY
(a)Disconnect the 2 vacuum hoses and the connector.
(b)Remove the 2 bolts and the vacuum reservoir.
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
4.REMOVE AIR CLEANER ASSY
(a)Disconnect the connector.
(b)Remove the air cleaner cap with the air cleaner hose.
(c)Remove the air cleaner filter element.
(d)Remove the 3 bolts and the air cleaner case.
5.REMOVE AIR TUBE NO.1 (See page 14±270) 6. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts and 2 upper infection pipe clampsfrom 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.
9. REMOVE INJECTION PIPE SUB±ASSY NO.4 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
10. REMOVE TIMING BELT NO.2 COVER
(a) Remove the 7 bolts and 7 seal washers, then remove the timing belt cover\
.
http://vnx.su