TOYOTA AVENSIS 2005 Service Repair Manual

A85632
A85631
SST
A85632
AA
B
A 11−52
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
28. INSTALL INJECTION PIPE SUB−ASSY NO.4
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
29. INSTALL FUEL PIPE NO.3
(a) Install 2 new gaskets, then temporarily install the bolt, 3
nuts and fuel pipe No. 3.
(b) Hold the hexagonal lobe of the exhaust fuel addition in-
jector assembly first. Using SST, tighten the nut of the fuel
pipe No. 3 to the injector side.
SST 09023−12700
Torque:
22 N
m (223 kgf
cm, 16 ft
lbf) with SST
24 N
m (240 kgf
cm, 17 ft
lbf) without SST
HINT:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter the injection pipe is reassembled, check that the
used pipe has no deflection and is installed properly. If it
has deflection or could not be installed properly, replace
the used pipe with a new pipe.
(c) Tighten the bolt and 3 nuts.
Torque:
5.0 N
m (51 kgf
cm, 44 in.
lbf) for bolt and nut A
27 N
m (275 kgf
cm, 20 ft
lbf) for nut B
(d) Install the fuel pipe insulator.

A84387
2to7mm0 to 5 mm *2
(0 to 0.1969 in.)
(0.0787 to
0.2756 in.)0 to 2 mm *1
*1: Turbocharger Side
*2: Intercooler Side(0 to 0.0787 in.)
A93662
Turbocharger Side:
Intercooler Side:Upward
Front90_
Clamp
90_ Bolt
Clamp
Bolt
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
11−53
AVENSIS Supplement (RM1045E)
30. INSTALL AIR TUBE NO.1
(a) Install the air hose and hose clamps as shown in the il-
lustration.
(b) Tighten the hose clamps as shown in the illustration.
Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
(c) Install the air tube No. 1 with the 3 bolts and nut.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
31. INSTALL AIR CLEANER ASSY
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
32. INSTALL ENGINE COVER SUB−ASSY NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
33. INSTALL VACUUM RESERVOIR SUB−ASSY
Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)

11−54
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
34. CHECK FOR FUEL LEAKS
NOTICE:
Under the ACTIVE TEST mode, the fuel pressure increases. Take precautions to prevent fuel from
spraying on you or inside the engine compartment.
HINT:
During the ACTIVE TEST mode, engine speed goes high and combustion noise becomes loud.
(a) Check that there are no fuel leaks from any parts of the fuel system when the engine is not running.
HINT:
If fuel leakage could be found on specific parts, replace them with new parts.
(b) While cranking or when starting the engine, check that there is no leaks from any parts of the fuel sys-
tem.
HINT:
If fuel leakage could be found on specific parts, replace them with new parts.
(c) Disconnect the fuel hose from the common rail.
(d) While cranking the engine, check fuel leaks from the return pipe.
HINT:
If there is fuel leakage, replace the common rail.
(e) Connect the hand−held tester to the DLC3.
(f) Start the engine, then turn the hand−held tester ON.
(g) Select the FUEL LEAK test of the ACTIVE TEST mode on the hand−held tester.
(h) If you do not have the hand−held tester, depress the accelerator pedal quickly and fully to increase
the engine speed to its maximum, then keep it for 2 seconds. Repeat this operation several times.
(i) Check that there are no leaks from any parts of the fuel system.
NOTICE:
If the leakage from the return pipe is less than 10 cc (0.6 cu in.) in a minute, it is acceptable.
HINT:
If fuel leakage could be found on specific parts, replace them with new parts.
(j) Reconnect the fuel hose to the common rail.

110U7−02
A85739
Radiator Support Opening Cover
Engine Cover Sub−assy 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)
x5
x2
x3
25 (255, 18)
Mass Air Flow Meter
Connector
6.0 (61, 53 in.
lbf)
6.0 (61, 53 in.
lbf)
11−44
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
INJECTOR ASSY (1CD−FTV)(From September, 2003)
COMPONENTS

A85740
Timing Belt No. 2 Cover
Seal Washer *
2Gasket
Injection Pipe
Clamp No. 2 zInjection
Pipe Sub−assy
13 (135, 9.8)
Cylinder Head Cover Sub−assy
Gasket
zNozzle Holder Seal
zGasket
zO−ring zFuel Injector Back−up Ring No. 1
zInjection Nozzle Seat Washer
Nozzle Holder ClampNozzle Leakage
Pipe Assy
Injector Assy
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable part
7.4 (75, 65 in.·lbf)
*131 (316, 23)
34 (347, 25)
20 (204, 15)
16 (163, 12)
27 (270, 20)
Nozzle Leakage Pipe No. 2
*
1Use SST
*2Replace only if damaged
*131 (316, 23)
34 (347, 25)
x10
x7
Fuel Pipe No. 3
zGasket
27 (270, 20)
8.8 (90, 78 in.·lbf)
5.0 (51, 44 in.·lbf)
*122 (223, 16)
24 (240, 17)
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
11−45
AVENSIS Supplement (RM1045E)

1111 7−01
A78441zNon−reusable part
N·m (kgf·cm, ft·lbf) : Specified torqueSeat Fixed Type:
Rear Seat Cushion Assy
Rear Floor Service Hole Cover
Fuel Pump Connector
Fuel Evaporation Tube
Sub−assy No. 2 Fuel Tank Main Tube
Sub−assy
Tube Joint ClipzFuel Pump Gauge Retainer
Fuel Suction
w/ Pump & Gauge Tube Assy
zFuel Suction Tube
Set Gasket x4
Fuel Tank Return Tube
11−28− FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (2AZ−FSE)
AVENSIS Supplement (RM1045E)
FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (2AZ−FSE)
COMPONENTS

1111 5−01
A84695
Mass Air Flow
Meter Connector
N·m (kgf·cm, ft·lbf) : Specified torqueEngine Cover Sub−assy
No. 1
9.0 (92, 80 in.
lbf)
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)
Air Cleaner Filter
Element Sub−assy x2
Air Cleaner Cap
Sub−assy
− FUELFUEL PUMP ASSY (2AZ−FSE)
11−21
AVENSIS Supplement (RM1045E)
FUEL PUMP ASSY (2AZ−FSE)
COMPONENTS

A84696zNon−reusable part
N·m (kgf·cm, ft·lbf) : Specified torqueThrottle Body AssyThrottle Control Motor
Connector
zThrottle Body Gasket
Water By−pass Hose
No. 2
Water By−pass Hose
No. 1
9.0 (90, 80 in.
lbf)
x4
x4
21 (210, 15)Throttle Body Bracket
8.4 (86, 74 in.
lbf)
Ground TerminalWiring Harness
Protector
8.4 (86, 74 in.
lbf)
11−22
− FUELFUEL PUMP ASSY (2AZ−FSE)
AVENSIS Supplement (RM1045E)

A84701
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable partzGasketzGasketFuel Tube Sub−assy
Fuel Pipe
Clamp
Fuel Pressure Pulsation
Damper Assy Fuel Pump Assy
zFuel Pump
Insulator
Fuel HoseFuel Pipe Sub−assy No. 1
zFuel Injector Back−up Ring No. 1
zFuel Injector Back−up Ring No. 2
zFuel Injector Back−up Ring No. 3
25 (255, 18)x2
zO−ring
9.0 (92, 80 in.
lbf)
30 (306, 22)
x2
33 (331, 24)
− FUELFUEL PUMP ASSY (2AZ−FSE)
11−23
AVENSIS Supplement (RM1045E)

1111 4−01
A88253
(a)
(b)
Pull Out
A88252
(a)
(b)
(c)
(d)
A77920
RHD:
LHD:
−
FUEL FUEL INJECTOR ASSY (2AZ −FSE)
11 −13
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11 −1)
2. REMOVE RADIATOR SUPPORT OPENING COVER (See page 10 −8)
3. REMOVE ENGINE ROOM COVER SIDE (See page 10 −8)
4. DISCONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL)
5. DRAIN ENGINE COOLANT (See page 16 −7)
6. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 10 −8)
7. REMOVE AIR CLEANER CAP SUB −ASSY (See page 10 −8)
8. REMOVE THROTTLE BODY ASSY (See page 10 −8)
9. REMOVE FUEL TUBE SUB −ASSY (See page 11 −24)
SST 09617 −24011
10. REMOVE FUEL HOSE (See page 11 −24)
11. REMOVE FUEL PIPE SUB −ASSY NO.1 (See page 11 −24)
SST 09023 −12900
12. REMOVE FUEL PUMP ASSY (See page 11 −24)
13. REMOVE CHARCOAL CANISTER ASSY
(a) Disconnect the fuel hose from the charcoal canister hose.
(b) Disconnect the charcoal canister outlet hose No. 1 from the charcoal canister.
(c) Pull out the charcoal canister from the charcoal canister base bracket.
14. REMOVE VACUUM SENSOR ASSY (LHD STEERING POSITION TYPE)
(a) Remove the wiring harness clamp.
(b) Disconnect the vacuum sensor connector.
(c) Disconnect the vacuum hose from the vacuum sensor.
(d) Remove the bolt, then remove the vacuum sensor.
15. REMOVE INTAKE MANIFOLD
(a) Disconnect the union to connector tube hose from the
brake booster.