2003 TOYOTA AVENSIS check

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

±
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

110U4±01
A78442
(a)
A78443
1
2
Tube Joint Clip
A60575
Nylon Tube
Fuel Tube Joint
O±ring Tube Joint Clip
Fuel Suction Plate
±
FUELFUEL PUMP ASSY(GASOLINE)
11±85
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
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 REAR FLOOR SERVICE HOLE COVER
(a) Remove the 4 screws, and then remove the rear floor ser-vice hole cover.
(b) Disconnect the fuel pump connector.
4. DISCONNECT FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE)
(a) Remove the tube joint clip, and pull out the fuel return tube.
NOTICE:

Check if there is any dirt or mud around the connector
before this operation and remove the dirt as neces-
sary.

Be careful of mud because the fuel tube joint has an
O±ring which seals the pipe and connector that can
be contaminated.

Do not use any tool in this operation.

Do not bend or twist the nylon tube. Protect the con-
nector by covering it with a vinyl or plastic bag.

When the pipe and connector are stuck, push and pull
the connector to release and pull the connector out
carefully.
http://vnx.su

A78444
2
1
Pinch1
Pinch
A75650
Tube ConnectorPipe
O±ring
Nylon Tube
A78445
2
Pinch
Pinch1
1
A65059
Nylon Tube
O±ringFuel Tube
Connector Clip
Fuel Tube
Connector Pipe
A78446
SST
Rib
11±86
±
FUEL FUEL PUMP ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
5. DISCONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a) Pinch the tube connector and pull out the fuel tank main tube.
NOTICE:

Check if there is any dirt or mud around the connector
before this operation and remove the dirt as neces-
sary.

Be careful of mud because the quick connector has
an O±ring which seals the pipe and connector that
can be contaminated.

Do not use any tool in this operation.

Do not bend or twist the nylon tube. Protect the con-
nector by covering it with a vinyl or plastic bag.

When the pipe and connector are stuck, push and pull
the connector to release and pull the connector out
carefully.
6. DISCONNECT FUEL EVAPORATION TUBE SUB±ASSY NO.2
(a) Pinch the fuel tube connector clip and pull out the fuel evaporation tube.
NOTICE:

Check if there is any dirt or mud around the connector
before this operation and remove the dirt as neces-
sary.

Be careful of mud because the quick connector has
an O±ring which seals the pipe and connector that
can be contaminated.

Do not use any tool in this operation.

Do not bend or twist the nylon tube. Protect the con-
nector by covering it with a vinyl or plastic bag.

When the pipe and connector are stuck, push and pull
the connector to release and pull the connector out
carefully.
7. REMOVE FUEL SUCTION W/PUMP & GAGE TUBE ASSY
(a) Using SST, loosen the fuel pump gauge retainer.
SST 09808±14010
NOTICE:
Do not use other tools in this operation. Damage to the fuel
pump gauge retainer and the fuel tank may result.
HINT:
A rib on the fuel pump gauge retainer can be fitted into a tip of
the SST.
http://vnx.su

A78447
A78448
Triangle Mark
Matchmark
A78446
SST
Rib
A78449
Arrow Mark
±
FUEL FUEL PUMP ASSY (GASOLINE)
11±87
AVENSIS REPAIR MANUAL (RM1018E)
(b) Remove the fuel pump gauge retainer.
(c) Remove the fuel suction w/ pump & gage tube.
NOTICE:
Be careful that the arm of the fuel sender gage should not
be bent.
(d) Remove the gasket from the tank.
8. INSTALL FUEL SUCTION W/PUMP & GAGE TUBE
ASSY
(a) Install a new gasket to the fuel tank.
(b) Install the fuel suction w/ pump & gage tube.
NOTICE:
Be careful that the arm of the fuel sender gage should not
be bent.
(c) Align the triangle mark of the fuel suction w/ pump & gage tube with the matchmark location the fuel tank.
(d) Temporarily install the fuel pump gauge retainer.
(e) Using SST, tighten the fuel pump gauge retainer until the arrow mark is aligned with the center mark on the fuel
tank.
SST 09808±14010
NOTICE:
Do not use other tools in this operation. Damage to the fuel
pump gauge retainer and the fuel tank may result.
HINT:
A rib on the fuel pump gauge retainer can be fitted into a tip of
the SST.
(f) Check that the arrow mark and center mark are aligned as shown in the illustration.
http://vnx.su

A81614
Push
A81615
Push
A81616
Tube Joint Clip
Collar
2
1
11±88
±
FUELFUEL 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)
http://vnx.su

SST
A50700
B00069
A16628A32859
±
FUEL FUEL SYSTEM (1AZ±FE)
11±23
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:
Injection volumeDifference between each injector
60 to 73 cm3 (3.6 to 4.5 cu in.)
in 15 seconds13 cm3 (0.9 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: 1 drop or less in 12 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

110UX±01
Fuel Tube Connector
A50710
A60083
Fuel Pipe
Clamp No.1
AA
B12941
±
FUELFUEL SYSTEM(1AZ±FE)
11±19
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1.CHECK FUEL PRESSURE
(a)Discharge the pressure in the fuel system and take pre-
cautions for possible fuel spillage.(See page 11±15)
(b) Check that the battery voltage is above 12 V.
(c) Disconnect the negative (±) battery cable.
(d) Pull out the connecter from a new fuel tube.
HINT:
Part No. 23901±0H040
(e) Remove the fuel pipe clamp No.1 from the fuel tube con- nector.
(f) Disconnect the fuel tube connector from the fuel pipe while pinching part A with fingers as shown in the illustra-
tion.
CAUTION:

Do not disconnect the fuel tube connector (quick
type) until after you have discharged the fuel system
pressure and taken appropriate steps to prevent fuel
spillage.

There may be remained pressure in the fuel lines after
discharging the pressure.
Take precautions to prevent fuel from spraying on
you or your clothing or inside the engine compart-
ment.
http://vnx.su