engine oil TOYOTA AVENSIS 2003 Service Service Manual

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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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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WRONG
CORRECT
Delivery Pipe
New O±ring
Injector
A51878
Delivery Pipe O±ring
Grommet
B09613
O±ring Retainer Pipe
Nylon Tube Housing
A50709
A75343
Fuel Pipe Clamp No.2
A60818
SST
11±16
±
FUEL FUEL SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Observe the following precautions when removing and installing fuel injectors.
NOTICE:
Never reuse the O±ring.
(1) When installing a new O±ring to the injector, becareful not to damage the injector.
(2) Coat the new O±ring with grease or gasoline before
installing. Never use engine oil, gear oil or brake oil.
(c) Install the injector to the delivery pipe and cylinder head as shown in the illustration. Before installing the injector,
be sure to apply grease or gasoline on the place where
the delivery pipe contacts the O±ring of the injector.
(d) Observe these precautions when disconnecting the fuel delivery pipe.
HINT:
The structure of the metallic connector is as shown in the il-
lustration on the left.
(1) Remove the fuel pipe clamp No.2.
(2) Find the metallic connector of the fuel tube assem-bly, slide it towards the vehicle rear and hold it as
it is.
(3) Assemble SST to the connection of the fuel pipe as shown the illustration.
SST 09268±21010
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B16534Push
B16535Pull
11±18
±
FUELFUEL SYSTEM(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(f)Observe these precautions when connecting the fuel tube connectors (Quick Type):
(1)Check that there is no damage or foreign objects inthe connected part of the pipe.
(2)Match the axis of the connector with the axis of the pipe, and push into the connector until the connec-
tor makes a ºclickº sound. If the connection is tight,
apply little amount of fresh engine oil on the tip of the
pipe.
(3)After having finished the connection, check if the pipe and the connector are securely connected by
pulling on them.
(4)Check for fuel leaks.
4.CHECK FOR FUEL LEAKS
(a)Check that there are no fuel leaks after doing maintenance anywhere on t\
he fuel system. (See page 11±19)
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O±ringDelivery Pipe
Injector CORRECT
WRONG
B10707
A75345
Delivery Pipe
Insulator Grommet
O±ring
Insulator
Delivery Pipe
O±ring
1ZZ±FE
3ZZ±FE
O±ring Retainer Pipe
Nylon Tube Housing
A50709
A75344
Fuel Pipe Clamp No.2
11±2
±
FUEL FUEL SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Observe the following precautions when removing and installing fuel injectors.
NOTICE:
Never reuse the O±ring.
(1) When installing a new O±ring on the injector, becareful not to damage the injector.
(2) Coat the new O±ring with grease or gasoline before
installing. Never use engine oil, gear oil or brake oil.
(c) Install the injector to the delivery pipe and cylinder head as shown in the illustration. Before installing the injector,
be sure to apply grease or gasoline on the place where
the delivery pipe contacts the O±ring of the injector.
(d) Observe these precautions when disconnecting the fuel delivery pipe.
HINT:
The structure of the metallic connector is as shown in the il-
lustration on the left.
(1) Remove the fuel pipe clamp No.2.
(2) Find the metallic connector of the fuel tube assem-bly, slide it towards the vehicle rear and hold it as
it is.
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A82344
Vinyl Bag or plastic Bag
B16534Push
B16535Pull
11±4
±
FUELFUEL SYSTEM(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(6)To prevent the disconnected pipe and connector from being damaged and foreign objects from being
introduced, cover them with a vinyl or plastic bag.
(f)Observe these precautions when connecting the fuel tube connectors (Quick Type):
(1)Check that there is no damage or foreign objects in
the connected part of the pipe.
(2)Match the axis of the connector with the axis of the pipe, and push into the connector until the connec-
tor makes a ºclickº sound. If the connection is tight,
apply little amount of fresh engine oil on the tip of the
pipe.
(3)After having finished the connection, check if the
pipe and the connector are securely connected by
pulling on them.
(4)Check for fuel leaks.
4.CHECK FOR FUEL LEAKS
(a)Check that there are no fuel leaks after doing maintenance anywhere on t\
he fuel system. (See page 11±5)
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A60083
Fuel Pipe
Clamp No.1
AA
B12941
B12944
A82344
Vinyl Bag or plastic Bag
±
FUEL FUEL SYSTEM (1AZ±FSE)
11±31
AVENSIS REPAIR MANUAL (RM1018E)
(b) Observe the following precautions when removing and
installing fuel injectors.
NOTICE:
Never reuse the O±ring.
(1) When installing a new O±ring to the injector, becareful not to damage the injector.
(2) Coat the new O±ring with grease or gasoline before
installing. Never use engine oil, gear oil or brake oil.
(c) Observe these following precautions when disconnecting the fuel tube connector (quick type).
(1) Remove the fuel pipe clamp No.1.
(2) Check that there is no dirt or mud on the pipe and
around the connector before disconnecting them.
Clean them if necessary.
(3) Disconnect the connector from the hose while pinching part A with fingers as shown in the illustra-
tion.
(4) When the connector and the pipe are stuck, push and pull the connector to release and pull the con-
nector out from the pipe carefully.
(5) Inspect that there is no dirt or mud on the sealing
surface of the disconnected pipe. Clean it away if
necessary.
(6) To prevent the disconnected pipe and connector from being damaged and foreign objects from being
introduced, cover them with a vinyl or plastic bag.
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B16534Push
B16535Pull
11±32
±
FUELFUEL SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(d)Observe these precautions when connecting the fuel tube connectors (Quick Type):
(1)Check that there is no damage or foreign objects inthe connected part of the pipe.
(2)Match the axis of the connector with the axis of the pipe, and push into the connector until the connec-
tor makes a ºclickº sound. If the connection is tight,
apply little amount of fresh engine oil on the tip of the
pipe.
(3)After having finished the connection, check if the pipe and the connector are securely connected by
pulling on them.
(4)Check for fuel leaks.
4.CHECK FOR FUEL LEAKS
(a)Check that there are no fuel leaks after doing maintenance anywhere on t\
he fuel system. (See page 11±33)
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A62779SST
A79153
A62166
SST
11±72
±
FUELINJECTION OR SUPPLY PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Using SST, remove the injection pump drive pulley. SST09950±50013 (09951±05010, 09952±05010, 09953±05020, 09954±05021)
36.REMOVE INJECTION OR SUPPLY PUMP ASSY
(a)Remove the 2 nuts and the injection pump.
37.INSTALL INJECTION OR SUPPLY PUMP ASSY Torque: 21 N
m (210 kgf
cm, 15 ft
lbf)
38.INSTALL INJECTION PUMP DRIVE PULLEY
(a)Using SST, install the pulley nut.SST09960±10010 (09962±01000, 09963±01000)
Torque: 64 N
m (650 kgf
cm, 47 ft
lbf)
39.INSTALL WATER INLET(See page 16±50)
40.INSTALL OIL LEVEL GAGE GUIDE(See page 17±22)
41. INSTALL INTAKE MANIFOLD INSULATOR NO.1 Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
42. INSTALL INJECTION PIPE SUB±ASSY NO.1
NOTICE:
When assembling the pipes, perform the operation with the
engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and vinyl tape from the common rail.
(b) Temporarily install the injection pipe.
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A79187
O±ringBack±up ring
B08249
A80111
180

90
11±62
±
FUEL INJECTOR ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install new back±up rings and O±rings to each injector.
(c) Apply a light coat of engine oil onto the O±rings on each injector.
(d) Install the injector to the cylinder head.
NOTICE:
Fit the injectors to the nozzle seat.
(e) Install the nozzle holder clamp as shown in the illustration. Tighten the camshaft bearing cap bolt by hand to fix the
nozzle holder clamp.
NOTICE:

Pay attention to the mounting orientation of the wash-
er.

When temporarily attaching the nozzle holder clamp
and the mounting bolt, be careful not to orient them
at an angle.
HINT:
Apply a light coat of engine oil on the threads of the nozzle hold-
er clamp bolts.
(f) Install the injection pipe No. 1, No. 2, No. 3 and No. 4,
tighten the nuts by hand.
(g) Install new 5 gaskets and the leakage pipe No. 1. Tighten
the 4 hollow screws by hand.
(h) Tighten the 4 nozzle holder clamp bolts. Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
(i) Remove the 4 injection pipes.
18. INSTALL NOZZLE LEAKAGE PIPE ASSY
(a) Install the nozzle leakage pipe and 5 new gaskets.
NOTICE:
When installing the gaskets, pay attention to the mounting
orientation. Install the gasket so that the joint portion of the
gasket comes within the ranges shown in the illustration.
(b) Apply a light coat of oil onto the 4 hollow screws and the union bolt.
(c) Tighten the 4 hollow screws and the union bolt by hand.
(d) Tighten the 4 hollow screws and the union bolt. Torque:
18 N
m (184 kgf
cm, 13 ft
lbf) for hollow screw
22 N
m (224 kgf
cm, 16 ft
lbf) for union bolt
(e) Check that there are no leaks from the nozzle leakage pipe connection.
(1) Disconnect the fuel hose, and remove the bolt, thecheck valve and the nozzle leakage No. 2 pipe and
the gasket.
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