fuel pump TOYOTA AVENSIS 2003 Service Service Manual

A75342
Battery4
5
±
FUEL FUEL SYSTEM (1AZ±FE)
11±21
AVENSIS REPAIR MANUAL (RM1018E)
(b) When not using hand±held tester
(1) Connect the positive (+) lead form the battery to ter-minal 4 of the connector and connect the negative
(±) lead to terminal 5.
(2) Check that the pump operates.
http://vnx.su

110UW±01
A75341
Fuel
Pump
Connector
B00679
Vinyl or Plastic Bag
±
FUELFUEL SYSTEM(1AZ±FE)
11±15
AVENSIS REPAIR MANUAL (RM1018E)
FUEL SYSTEM(1AZ±FE)
PRECAUTION
1.PRECAUTION
(a)Before working on fuel system, disconnect negative (±) battery cable.
(b)Do not smoke or work near fire when handling the fuel system.
(c)Keep gasoline away from rubber or leather parts.
2.DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:

Do not disconnect any part of the fuel system until
you have discharged the fuel system pressure.

Even after discharging the fuel pressure, place a
shop rag over fittings as you separate them to reduce
risk of fuel spray on yourself or in the engine compart-
ment.
(a)Disconnect the fuel pump connector.
(b)Start the engine. After the engine has stopped, turn the ignition switch OFF.
(c)Disconnect the negative (±) battery cable.
(d)Connect the fuel pump connector.
3.FUEL SYSTEM
(a)When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these proce-
dures.
(1)Discharge the pressure in the fuel system. (See step 2)
(2)Disconnect the fuel pump tube. (See page 11±93)
(3) Drain the fuel that remained inside the fuel pump
tube.
(4) Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt.
(5) Place a tray under the vehicle or point of disconnec- tion to catch any fuel that may spill.
http://vnx.su

110CX±02
A75346
A79038
E2S PR2 VCSVC PR E2
Fuel pressure sensor
A79039Pressure discharge valve
A62162
Vacuum
Switch Body
11±56
±
FUEL FUEL SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
FUEL SYSTEM (1CD±FTV)
INSPECTION
1. INJECTION OR SUPPLY PUMP ASSY
(a) Resistance inspection. (1) Using an ohmmeter, measure the resistance be-tween the terminals.
Resistance: 1.5 to 2.3  at 20
C (68
F)
2. INJECTOR ASSY
(a) Resistance inspection. (1) Using an ohmmeter, measure the resistance between the terminals.
Resistance: 0.85 to 1.05  at 20
C (68
F)
3. COMMON RAIL ASSY
(a) Resistance inspection. (Fuel pressure sensor) (1) Using an ohmmeter, measure the resistance be-tween terminals 5 (PR) and 4 (E2).
Resistance: 16.4 k or less
(2) Using an ohmmeter, measure the resistance be- tween terminals 2 (PR2) and 3 (E2S).
Resistance: 16.4 k or less
(3) Using an ohmmeter, measure the resistance be-
tween terminals 6 (VC) and 5 (PR).
Resistance: 3 k or less
(4) Using an ohmmeter, measure the resistance be- tween terminals 1 (VCS) and 2 (PR2).
Resistance: 3 k or less
(b) Resistance inspection. (Pressure discharge valve) (1) Using an ohmmeter, measure the resistance be-tween terminals.
Resistance: 0.85 to 1.05  at 20
C (68
F)
4. FUEL HEATER ASSY
(a) Resistance inspection. (1) Apply a vacuum of 34.7
5.3 kPa (260
40
mmHg, 10.24
1.57 in Hg) to the vacuum switch
port.
(2) Using an ohmmeter, measure the resistance be- tween terminal 2 and switch body.
Resistance: 0.5 to 20  at 20
C (68
F)
http://vnx.su

110UV±01
Fuel Tube Connector
A50710
Fuel Tube Connector
SST
(Hose)
B12947
SST (Hose)SST
(Clamp)
Vinyl Tube SST (Union)
O±Ring
A51875
11±8
±
FUELFUEL SYSTEM(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1.FUEL INJECTOR ASSY
(a)Inspect injector resistance (1)Using an ohmmeter, measure the resistance be-tween the terminals.
Resistance:
EngineRersistanceCondition
1ZZ±FE13.4 to 14.2
20
C (68
F)
3ZZ±FE13.8 to 15.2
20
C (68
F)
If the resistance is not as specified, replace the injector.
(b)Inspect injector inspection
CAUTION:
This test involves high±pressure fuel and electricity. Take
every precaution regarding safe handling of both the fuel
and the electricity. Preform this test in a safe area, and
avoid any sparks or flame. Do not smoke.
(1)Obtain new No. 1 fuel pipe (part No. 23901±0D030)and remove the fuel tube connector from the pipe.
(2)Install the fuel tube connector to SST (hose), then connect the tube connector and the fuel pipe.
SST09268±41047 (95336±08070)
CAUTION:
Connect the fuel tube connector (quick type) after observ-
ing the precautions to prevent fuel from spraying.
(3)Install the O±ring to the injector.
(4)Connect SSTs (union and hose) to the injector, andhold the injector and the union with SST (clamp)
SST09268±41047 (95336±08070, 09268±41110, 09268±41300)
(5)Put the injector into a graduated cylinder.
CAUTION:
Install a suitable vinyl tube onto the injector to contain gas-
oline spray.
(6)Operate the fuel pump.(See Page 11±5)
http://vnx.su

SST
A50700
B00069
A16628A32859
±
FUEL FUEL SYSTEM (1ZZ±FE/3ZZ±FE)
11±9
AVENSIS REPAIR MANUAL (RM1018E)
(7) Connect SST (wire) to the injector and the battery
for 15 seconds, and measure the injection volume
with a graduated cylinder. Test each injector 2 or 3
times.
SST 09842±30080
Injection volume:
EngineInjection volumeDifference between each
injector
1ZZ±FE
60 to 73 cm3
(3.7 to 4.5 cu in.)in 15 seconds13 cm3 (0.8 cu in.) or less
3ZZ±FE
45 to 55 cm3
(2.7 to 3.3 cu in.)in 15 seconds10 cm3 (0.6 cu in.) or less
NOTICE:
Always do the switching at the battery side.
If the injection volume is not as specified, replace the injector.
(c) Inspect leakage (1) In the condition above, disconnect the test probesof SST (wire) from the battery and check the fuel
leakage from the injector.
Fuel drop:
1ZZ±FE1 drop or less in 12 minutes
3ZZ±FE1 drop or less in 5 minutes
2. INSPECT FUEL PUMP
(a) Insect fuel pump resistance.
(1) Using an ohmmeter, measure the resistance be-tween the terminals.
Resistance: 0.2 to 3.0
at 20 C (68 F)
(b) Inspect fuel pump operation (1) Apply battery voltage to both the terminals. Checkthat the pump operates.
NOTICE:

These tests must be done quickly (within 10 seconds)
to prevent damage to the pump.

Keep fuel pump as far away from the battery as pos-
sible.

Always do the switching at the battery side.
http://vnx.su

No.1 Fuel Pipe
Fuel Tube Connector
SST
(Clip)
SST (T joint)SST
SST
(Hose)
B12975
11±6
±
FUEL FUEL SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(g) Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration.
SST 09268±41047(95336±08070),09268±45014 (09268±41250, 09268±41200, 09268±41220)
(h) Wipe up any gasoline.
(i) Reconnect the negative (±) battery cable.
(j) Connect the hand±hand tester to the DLC3.
(k) Measure the fuel pressure. Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check the fuel hoses connections, the fuel
pump, the fuel filter and the fuel pressure regulator.
(l) Disconnect the hand±held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle. Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure:147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, the pres-
sure regulator and/or the injectors.
(q) After checking the fuel pressure, disconnect the negative (±) battery cable and carefully remove SST and the fuel
tube connector to prevent gasoline from splashing.
(r) Reconnect the No. 1 fuel pipe (fuel tube connector).
CAUTION:
After taking the precautions, connect the fuel tube con-
necter (quick type).
2. CHECK FUEL PUMP OPERATION AND FUEL LEAK
(a) When using the hand±held tester (1) Connect the hand±held tester to the DLC3.
(2) Turn the ignition switch ON and the hand±held tes-
ter main switch ON.
NOTICE:
Do not start the engine. (3) Select the active test mode on the hand±held tester.
(4) Perform the active test. Check that the fuel pumpoperates and check for fuel leaks.
http://vnx.su

A75342
Battery4
5
±
FUEL FUEL SYSTEM (1ZZ±FE/3ZZ±FE)
11±7
AVENSIS REPAIR MANUAL (RM1018E)
(b) When not using the hand±held tester
(1) Connect the positive (+) lead form the battery to ter-minal 4 of the connector and connect the negative
(±) lead to terminal 5.
(2) Check that the pump operates.
http://vnx.su

110UT±01
A75341
Fuel
Pump
Connector
B00679
Vinyl or Plastic Bag
±
FUELFUEL SYSTEM(1ZZ±FE/3ZZ±FE)
11±1
AVENSIS REPAIR MANUAL (RM1018E)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
PRECAUTION
1.PRECAUTION
(a)Before working on fuel system, disconnect negative (±) battery cable.
(b)Do not smoke or work near fire when handling the fuel system.
(c)Keep gasoline away from rubber or leather parts.
2.DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:

Do not disconnect any part of the fuel system until
you have discharged the fuel system pressure.

Even after discharging the fuel pressure, place a
shop rag over fittings as you separate them to reduce
risk of fuel spray on yourself or in the engine compart-
ment.
(a)Disconnect the fuel pump connector.
(b)Start the engine. After the engine has stopped, turn the ignition switch OFF.
(c)Disconnect the negative (±) battery cable.
(d)Connect the fuel pump connector.
3.FUEL SYSTEM
(a)When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these proce-
dures.
(1)Discharge the pressure in the fuel system. (See step 2)
(2) Disconnect the fuel pump tube. (See page 11±93)
(3) Drain the fuel that remained inside the fuel pump tube.
(4) Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt.
(5) Place a tray under the vehicle or point of disconnec-
tion to catch any fuel that may spill.
http://vnx.su

110V1±01
A16628A32859
B10599
Ohmmeter
11±36
±
FUEL FUEL SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT FUEL INJECTOR ASSY
NOTICE:
This inspection aims at inspecting the fuel injectors for open or short, bec\
ause the fuel injectors of
this vehicle are high±pressure type and do not allow to inspect fuel inje\
ction volume.
(a) Inspect injector resistance (1) Using an ohmmeter, measure the resistance between the terminals.
Resistance: 2.55 to 2.85 at 20 C (68 F)
If the resistance is not as specified, replace the injector.
2. INSPECT FUEL PUMP
(a) Insect fuel pump resistance.(1) Using an ohmmeter, measure the resistance be-tween the terminals.
Resistance: 0.2 to 3.0  at 20 C (68 F)
(b) Inspect fuel pump operation
(1) Apply battery voltage to both the terminals. Checkthat the pump operates.
NOTICE:

These tests must be done quickly (within 10 seconds)
to prevent damage to the pump.

Keep fuel pump as far away from the battery as pos-
sible.

Always do the switching at the battery side.
3. INSPECT FUEL PUMP (HIGH PRESSURE)
(a) Remove the engine cover.
(b) Disconnect the fuel pump connector.
(c) Using an ohmmeter, measure the resistance between the
terminals.
Resistance: 1.19 to 1.39  at 20 C (68 F)
If the resistance is not as specified, replace the fuel pump.
(d) Reconnect the connector.
(e) Reinstall the engine cover.
http://vnx.su

No.1 Fuel Pipe
Fuel Tube Connector
SST
(Clip)
SST (T joint)SST
SST
(Hose)
B12975
11±34
±
FUEL FUEL SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(g) Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration.
SST 09268±41047(95336±08070),09268±45014 (09268±41250, 09268±41200, 09268±41220)
(h) Wipe up any gasoline.
(i) Reconnect the negative (±) battery cable.
(j) Connect the hand±hand tester to the DLC3.
(k) Measure the fuel pressure. Fuel pressure:
196 to 588 kPa (2 to 6 kgf/cm
2, 28 to 85 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check the fuel hoses connections, the fuel
pump, the fuel filter and the fuel pressure regulator.
(l) Disconnect the hand±held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle. Fuel pressure:
196 to 588 kPa (2 to 6 kgf/cm
2, 28 to 85 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure:147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, the pres-
sure regulator and/or the injectors.
(q) After checking the fuel pressure, disconnect the negative (±) battery cable and carefully remove SST and the fuel
tube connector to prevent gasoline from splashing.
(r) Reconnect the No. 1 fuel pipe (fuel tube connector).
CAUTION:
After taking the precautions, connect the fuel tube con-
necter (quick type).
2. CHECK FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS
(a) When using the hand±held tester
(1) Connect the hand±held tester to the DLC3.
(2) Turn the ignition switch ON and the hand±held tes-ter main switch ON.
NOTICE:
Do not start the engine.
(3) Select the active test mode on the hand±held tester.
(4) Perform the active test. Check that the fuel pumpoperates and check for fuel leaks.
http://vnx.su