2005 TOYOTA AVENSIS fuel pressure

110TD±01
A79578
A79579
A79580
11±42
±
FUEL FUEL INJECTOR ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
2.REMOVE RADIATOR SUPPORT OPENING COVER (See page 18±16)
3.REMOVE ENGINE ROOM COVER SIDE (See page 18±17)
4.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 10±44)
5.DRAIN ENGINE COOLANT (See page 16±31)
6.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±44)
7.REMOVE THROTTLE BODY ASSY (See page 10±44)
8. REMOVE CHARCOAL CANISTER ASSY
9.REMOVE ENGINE COVER BRACKET (See page 11±52)
10.REMOVE FUEL PUMP ASSY(See page 11±52) 11. REMOVE INTAKE MANIFOLD
(a) Remove the ventilation hose No. 1.
(b) Disconnect the 2 vacuum hoses from the VSV.
(c) Disconnect the union to connector tube hose from thebrake booster assy.
(d) Remove the 5 bolts and 2 nuts from the intake manifold.

A79584
A79585
A79586
A79587
A79588
11±44
± FUELFUEL INJECTOR ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(h) Remove the intake manifold.
12. REMOVE SURGE TANK STAY NO.1
(a) Disconnect the wire harness from the surge tank stay
No.1.
(b) Remove the 3 bolts and the surge tank stay No.1.
13. REMOVE INTAKE MANIFOLD INSULATOR NO.2
(a) Disconnect the fuel injector assy connector and the knock
sensor connector.
(b) Remove the intake manifold insulator No.2 from the cylin-
der block.
14. REMOVE NOZZLE HOLDER CLAMP
(a) Using a Torx socket (T±40), remove the nozzle holder
clamp.
15. REMOVE FUEL DELIVERY PIPE SUB±ASSY
(a) Disconnect the fuel pressure sensor connector.
(b) Disconnect the fuel hose from the fuel delivery pipe sub±
assy.
(c) Remove the 5 bolts.
(d) Remove the fuel injector and the fuel delivery pipe sub±
assy together.

A79592
5
A79593
A79594
11±46
± FUELFUEL INJECTOR ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Install the fuel injector to the fuel delivery pipe as shown
in the illustration.
NOTICE:

Be careful not to damage the sealing surface of the
fuel delivery pipe when installing the injector.

Check that there are no damages and foreign objects
in the fuel injector mounting hole of the fuel delivery
pipe sub±assy.

In order to avoid damaging, be sure to apply fuel to
both the O±ring and the mounting hole before instal-
ling the fuel injector to the fuel delivery pipe.
18. INSTALL FUEL DELIVERY PIPE SUB±ASSY
(a) Install a new gasket and a new fuel injector seal to the cyl-
inder head.
NOTICE:
Pay attention the mounting orientation of the fuel injector
seal.
(b) Install the fuel delivery pipe sub±assy and the fuel injector
assy together to the cylinder head.
NOTICE:

Remove carbon from the tip of the fuel injector if nec-
essary.

Since the fuel injector tip is sensitive,do not give
physical impact to the tip.

If you mistakenly drop the fuel injector, replace it with
a new one.

Check that there are no damages and foreign objects
on the fuel injector mounting area of the cylinder
head.
(c) Temporarily install the fuel delivery pipe sub±assy with
the 5 bolts.
19. INSTALL NOZZLE HOLDER CLAMP
(a) Align the keyway of the fuel injector with the nozzle holder
clamp and fit them.
(b) Using a Torx socket (T±40), instal the nozzle holder clamp
to the cylinder head.
Torque: 13 N
m (127 kgf
cm, 9 ft
lbf)
(c) Tighten the 5 bolts until they reach the specified torque to
secure the fuel delivery pipe sub±assy.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
(d) Connect the fuel hose to the fuel delivery pipe sub±assy.
(e) Connect the fuel pressure sensor connector.
20. INSTALL INTAKE MANIFOLD INSULATOR NO.2
(a) Install the intake manifold insulator No. 2 to the cylinder block.
(b) Connect the fuel injector assy connector and the knock sensor connector.

A79577
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket
GasketFuel Tube Sub±assy
Fuel Pipe Clamp
Fuel Pressure Pulsation
Damper Assy Fuel Pump Assy

Fuel Pump
Insulator
Fuel HoseFuel Pipe Sub±assy No. 1

Fuel Injector Back±up Ring No. 1
25 (255, 18)
33 (331, 24)
9.0 (92, 80 in.
lbf)
38 (388, 28 )
30 (306, 22)

Fuel Injector Back±up Ring No. 2

Fuel Injector Back±up Ring No. 3
O±ring
Engine Cover Bracket
± FUELFUEL INJECTOR ASSY (1AZ±FSE)
11±39
AVENSIS REPAIR MANUAL (RM1018E)

110V1±01
A16628A32859
B10599
Ohmmeter 11±36
± FUELFUEL 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, because the fuel injectors of
this vehicle are high±pressure type and do not allow to inspect fuel injection volume.
(a) Inspect injector resistance
(1) Using an ohmmeter, measure the resistance between the terminals.
Resistance: 2.55 to 2.85at 20C (68F)
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 20C (68F)
(b) Inspect fuel pump operation
(1) Apply battery voltage to both the terminals. Check
that 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 20C (68F)
If the resistance is not as specified, replace the fuel pump.
(d) Reconnect the connector.
(e) Reinstall the engine cover.

110V0±01
Fuel Tube Connector
A50710
A60083
Fuel Pipe
Clamp No.1
AA
B12941
±
FUEL FUEL SYSTEM(1AZ±FSE)
11±33
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±30)
(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±28160
(e) Disconnect the fuel tube clamp from the fuel tube connec- tor.
(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.

No.1 Fuel Pipe
Fuel Tube Connector
SST
(Clip)
SST (T joint)SST
SST
(Hose)
B12975
11±34
± FUELFUEL 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 pump
operates and check for fuel leaks.

A75340
Battery4
5

B12608
A76859
Hand±held Tester
± FUELFUEL SYSTEM (1AZ±FSE)
11±35
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.
3. CHECK FUEL PUMP OPERATION (HIGH PRESSURE)
(a) Remove the No. 1 engine cover.
(b) Start the engine.
(c) Using a sound scope, hear the operating sound of the
pump.
If there is no sound, replace the pump.
(d) Stop the engine.
(e) Reinstall the engine cover.
4. CHECK FUEL HIGH PRESSURE
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine.
(c) Select the active test mode on the hand±held tester.
(d) Perform the active test check the fuel high pressure at idle
to 3,000 rpm.
Fuel high pressure:
9.5 to 10.5 Mpa (97 to 107 kgf/cm
2, 1,380 to 1,520 psi)
If the pressure is not as specified, check the fuel pump, high
pressure fuel pump, fuel pressure sensor, wiring and fuel leak-
age.
(e) Stop the engine.
(f) Disconnect the hand±held tester.