fuel type TOYOTA AVENSIS 2005 Service Service Manual

A81614
Push
A81615
Push
A81616
Tube Joint Clip
Collar
2
1
11±88
±
FUEL FUEL PUMP ASSY(GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
9.CONNECT FUEL EVAPORATION TUBE SUB±ASSY NO.2
(a)Push in the fuel tube 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 fuel tube connector and
the pipe are securely connected by pulling on them.
10.CONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a)Push in the fuel tube 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 fuel tube connector and
the pipe are securely connected by pulling on them.
11.C ONNECT FUEL TANK RETURN TUBE (1AZ±F SE
ENGINE TYPE)
(a)Install in the fuel return tube with the tube joint clip.
NOTICE:

Check that there is no scratch or foreign objects on
the connecting part.

Check that the fuel tube joint is inserted securely.

Check that the tube joint clip is on the collar of the fuel
tube joint.

After installing the tube joint clip, check that the fuel
tube joint has not been pulled off.
12.CHECK FOR FUEL LEAKS
HINT:

1ZZ±FE/3ZZ±FE: 11±5

1AZ±FE: 11±19

1AZ±FSE: 11±33
13.INSTALL REAR FLOOR SERVICE HOLE COVER
14.INSTALL REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 72±32)

110U3±01
A78441
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torqueSeat Fixed Type:
Rear Seat Cushion Assembly
Rear Floor Service Hole Cover
Fuel Pump Connector
Fuel Evaporation Tube
Sub±assy No. 2 Fuel Tank Main Tube
Sub±assy
Tube Joint Clip
Fuel Pump Gauge Retainer
Fuel Suction
w/ Pump & Gage Tube Assy

Fuel Suction Tube
Set Gasket x4
1AZ±FSE:
Fuel Tank Return Tube
11±84
± FUELFUEL PUMP ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
FUEL PUMP ASSY (GASOLINE)
COMPONENTS

110U5±01
A78493
A80060
w/o HID Sensor:
w/ HID Sensor:
(c)
(d)
(c)
±
FUEL FUEL TANK ASSY(GASOLINE)
11±93
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.DISCHARGE FUEL SYSTEM PRESSURE
HINT:

1ZZ±FE/3ZZ±FE: 11±1

1AZ±FE: 11±15

1AZ±FSE: 11±30
2.REMOVE REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 72±32)
3.REMOVE COVER, RR FLOOR SERVICE HOLE (See page 11±85)
4.DISCONNECT FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE)
(See page 11±85)
5.DISCONNECT FUEL TANK MAIN TUBE SUB±ASSY (See page 11±85)
6.DISCONNECT FUEL EVAPORATION TUBE SUB±ASSY NO.2 (See page 11±85)
7.REMOVE FUEL SUCTION W/PUMP & GAGE TUBE ASSY (See page 11±85)
SST 09808±14010
8. DRAIN FUEL
9. REMOVE FRONT FLOOR FOOTREST (W/O HID SENSOR)
10.REMOVE FLOOR PANEL BRACE FRONT (See page 15±2)
11. REMOVE EXHAUST PIPE ASSY CENTER(1ZZ±FE/3ZZ±FE ENGINE TYPE)
(a) Using a clip remover, remove the 2 clips. (w/o HID Sensor)
(b) Open the floor carpet. (w/o HID Sensor)
(c) Disconnect the heated oxygen sensor connector.
(d) Remove the grommet. (w/o HID Sensor)

A78519
(a)
(b)
(a)(b)
(a)
(a)
A77883
A77884
± FUELFUEL TANK ASSY (GASOLINE)
11±95
AVENSIS REPAIR MANUAL (RM1018E)
12. REMOVE EXHAUST PIPE ASSY CENTER
(1AZ±FE/1AZ±FSE ENGINE TYPE)
(a) Remove the 4 bolts and 2 compression springs.
(b) Remove the exhaust pipe center and the gasket from the
2 exhaust pipe supports.
(c) Remove the gasket from the exhaust pipe center.
13. REMOVE FUEL TANK PROTECTOR NO.1
(a) Remove the 4 bolts, and then remove the fuel tank pro-
tector.
14. REMOVE PARKING BRAKE CABLE ASSY NO.2
(a) Remove the 2 set bolts of the parking brake cable.

A77885
A77886
A77887
A78450
11±96
± FUELFUEL TANK ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
15. REMOVE PARKING BRAKE CABLE ASSY NO.3
(a) Remove the 2 set bolts of the parking brake cable.
16. DISCONNECT BREATHER TUBE FUEL HOSE
(a) Loosen the hose clamp and disconnect the fuel tank
breather hose.
17. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
(a) Loosen the hose clamp and disconnect the fuel tank to fill-
er pipe hose.
18. DISCONNECT FUEL TANK RETURN TUBE (1AZ±FSE
ENGINE TYPE)

A77894
A77891
A77892
A77893
Upper
Fuel Tank
Rear
Hose Clamp
A81617
Push 11±98
± FUELFUEL TANK ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
22. REMOVE FUEL TANK RETURN TUBE (1AZ±FSE
ENGINE TYPE)
(a) Unfasten the 5 claws and remove the fuel tank return tube
from the fuel tank.
23. REMOVE FUEL EVAPORATION TUBE SUB±ASSY
NO.2
(a) Unfasten the 4 claws and remove the fuel evaporation
tube from the fuel tank.
24. REMOVE FUEL TANK MAIN TUBE SUB±ASSY
(a) Unfasten the 4 claws and remove the fuel tank main tube
from the fuel tank.
25. INSTALL FUEL TANK MAIN TUBE SUB±ASSY
26. INSTALL FUEL EVAPORATION TUBE SUB±ASSY
NO.2
(a) Install the hose clamp as shown in the illustration.
27. INSTALL FUEL TANK RETURN TUBE (1AZ±FSE
ENGINE TYPE)
28. INSTALL FUEL TANK ASSY
Torque: 40 N
m (400 kgf
cm, 29 ft
lbf)
29. CONNECT FUEL EVAPORATION TUBE SUB±ASSY
NO.2
(a) Push in the fuel tube 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 fuel tube connector and
the pipe are securely connected by pulling on them.

A81618
Push
2
1
Retainer
A77857
A78440
New Gasket
A77857
± FUELFUEL TANK ASSY (GASOLINE)
11±99
AVENSIS REPAIR MANUAL (RM1018E)
30. CONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a) Push in the fuel tube connector to the pipe until it makes
ºclickº sound, and then push up the retainer to the claws
lock.
NOTICE:

Check if there is any damage or foreign objects on the
connected part.

After connecting, check if the fuel tube connector and
the pipe are securely connected by pulling on them.
31. CONNECT FUEL TANK RETURN TUBE (1AZ±FSE
ENGINE TYPE)
32. CONNECT FUEL TANK TO FILLER PIPE HOSE
33. CONNECT BREATHER TUBE FUEL HOSE
34. INSTALL PARKING BRAKE CABLE ASSY NO.3
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
35. INSTALL PARKING BRAKE CABLE ASSY NO.2
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
36. INSTALL FUEL TANK PROTECTOR NO.1
Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
37. INSTALL EXHAUST PIPE ASSY CENTER
(1ZZ±FE/3ZZ±FE ENGINE TYPE)
(a) Compression spring inspection
(1) Using vernier calipers, measure the free length of
the compression spring.
Minimum length:
41.5 mm (1.634 in.) for front x manifold
38.5 mm (1.516 in.) for front x tail
If the free length is less than minimum, replace the compression
spring.
(b) Install each new gasket to the exhaust manifold and the
exhaust pipe front as shown in the illustration.
(c) Install the exhaust pipe front to the 2 exhaust pipe sup-
ports
(d) Tighten the 4 compression springs and 4 bolts.
Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
(e) Install the grommet. (w/o HID Sensor)
(f) Connect the heated oxygen sensor connector.
(g) Install the floor carpet with the 2 clips. (w/o HID Sensor)
38. INSTALL EXHAUST PIPE ASSY CENTER
(1AZ±FE/1AZ±FSE ENGINE TYPE)
(a) Compression spring inspection
(1) Using vernier calipers, measure the free length of
the compression spring.
Minimum length: 38.5 mm (1.516 in.)
If the free length is less than minimum, replace the compression
spring.

A78440
New Gasket
11±100
±
FUEL FUEL TANK ASSY(GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install a new gasket to the the exhaust pipe center (ex- haust pipe tail side) as shown in the illustration.
(c)Install a new gasket (exhaust pipe front side) and the ex-
haust pipe center to the 2 exhaust pipe supports.
(d)Tighten the 2 compression springs and 4 bolts. Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
39.ADD FUEL
40.INSTALL FUEL SUCTION W/PUMP & GAGE TUBE ASSY (See page 11±85) SST 09808±14010
41.CONNECT FUEL EVAPORATION TUBE SUB±ASSY NO.2 (See page 11±85)
42.CONNECT FUEL TANK MAIN TUBE SUB±ASSY (See page 11±85)
43.CONNECT FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE) (See page 11±85)
44. CHECK FOR FUEL LEAKS
HINT:

1ZZ±FE/3ZZ±FE: 11±5

1AZ±FE: 11±19

1AZ±FSE: 11±33
45. CHECK FOR EXHAUST GAS LEAKS
46.INSTALL FLOOR PANEL BRACE FRONT (See page 15±2)
47. INSTALL REAR FLOOR SERVICE HOLE COVER
48.INSTALL REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 72±32)
49. INSTALL FRONT FLOOR FOOTREST (W/O HID SENSOR)

110U6±01
A78441
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torqueSeat Fixed Type:
Rear Seat Cushion Assembly
Rear Floor Service Hole Cover
Fuel Pump Connector
Fuel Evaporation Tube
Sub±assy No. 2 Fuel Tank Main Tube
Sub±assy
Tube Joint Clip
Fuel Pump Gauge Retainer
Fuel Suction
w/ Pump & Gage Tube Assy

Fuel Suction Tube
Set Gasket x4
1AZ±FSE:
Fuel Tank Return Tube
± FUELFUEL TANK ASSY (GASOLINE)
11±89
AVENSIS REPAIR MANUAL (RM1018E)
FUEL TANK ASSY (GASOLINE)
COMPONENTS

A76714
A78459
14±44
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
137. INSTALL BATTERY CARRIER
(a) Install the battery carrier and bracket with the 4 bolts. Torque: 12.8 N
m (131 kgf
cm, 9 ft
lbf)
138. INSTALL BATTERY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
139. INSTALL RADIATOR SUPPORT NO.1
(a) Install the 2 radiator supports with the 2 bolts. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
140.INSTALL ACCELERATOR CONTROL CABLE ASSY (1ZZ±FE ENGINE TYPE) (See page 10±9)
141.INSTALL ACCELERATOR CONTROL CABLE ASSY (3ZZ±FE ENGINE TYPE) (See page 10±15)
142. INSTALL AIR CLEANER CASE SUB±ASSY
(a) Install the air cleaner case with the 3 bolts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
143.INSTALL AIR CLEANER ASSEMBLY WITH HOSE (See page 10±9 or 10±15)
144. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips.Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
145. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
146. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
147. ADD ENGINE OIL
148.ADD ENGINE COOLANT (See page 16±7)
149. CHECK FOR ENGINE OIL LEAKS
150.CHECK FOR ENGINE COOLANT LEAKS(See page 16±7)
151. CHECK FOR FUEL LEAKS
152. CHECK FOR EXHAUST GAS LEAKS
153.CHECK IDLE SPEED AND IGNITION TIMING(See page 14±1)
SST 09843±18040
154.INSPECT CO/HC(See page 14±1)
155.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
156. CHECK ABS SPEED SENSOR SIGNAL