Page 1897 of 5135

110U4±01
A78442
(a)
A78443
1
2
Tube Joint Clip
A60575
Nylon Tube
Fuel Tube Joint
O±ring Tube Joint Clip
Fuel Suction Plate
±
FUEL FUEL 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.
Page 1898 of 5135

A78444
2
1
Pinch1
Pinch
A75650
Tube Connector
Pipe O±ring Nylon Tube
A78445
2
Pinch
Pinch1
1
A65059
Nylon TubeO±ringFuel Tube
Connector Clip
Fuel Tube
ConnectorPipe
A78446
SST
Rib
11±86
± FUELFUEL 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.
Page 1899 of 5135

A78447
A78448
Triangle Mark
Matchmark
A78446
SST
Rib
A78449
Arrow Mark
± FUELFUEL 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.
Page 1900 of 5135

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)
Page 1901 of 5135
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
Page 1902 of 5135

110UD±01
A79188
A80091SST
A79190
11±82
± FUELFUEL FILTER ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
FUEL FILTER ASSY (1CD±FTV)
REPLACEMENT
1. REMOVE AIR CLEANER ASSY
(a) Disconnect the connector.
(b) Remove the air cleaner cap with the air cleaner hose.
(c) Remove the air cleaner filter element.
(d) Remove the 3 bolts and the air cleaner case.
2. REMOVE FUEL FILTER ASSY
(a) Disconnect the 2 fuel hose from the fuel filter. (STD or COLD)
(b) Disconnect the 3 fuel hose from the fuel filter. (W/ ADDTIONAL HEATER)
(c) Disconnect the 2 connectors.
(d) Remove the 2 bolts and the fuel filter.
3. DRAIN FUEL
(a) Loosen the drain plug, and drain the fuel from the fuel filter.
4. REMOVE LEVEL WARNING SWITCH
(a) Clamp the fuel filter in a soft jaw vise.
(b) Using pliers, remove the level warning switch.
NOTICE:
Be careful not to damage the level warning switch.
5. REMOVE FUEL FILTER ELEMENT
(a) Using SST, remove the fuel filter element.
SST 09228±64030
6. INSTALL FUEL FILTER ELEMENT
(a) Check and clean the fuel filter installation surface.
(b) Apply fuel to a gasket of a new fuel filter element.
(c) Lightly screw the fuel filter element into place, and tighten
it until the gasket comes into contact with the seat.
(d) Tighten it additional 3/4 turn by hand.
Page 1903 of 5135
±
FUEL FUEL FILTER ASSY(1CD±FTV)
11±83
AVENSIS REPAIR MANUAL (RM1018E)
7.INSTALL LEVEL WARNING SWITCH
(a)Install a new O±ring to the level warning switch.
(b)Apply fuel to the O±ring of the level warning switch.
(c)Install the level warning switch to the fuel filter by hand.
8.INSTALL FUEL FILTER ASSY
Torque: 18 N m (178 kgf cm, 13 ft lbf)
9.INSTALL AIR CLEANER ASSY
Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
10.CHECK FOR FUEL LEAKS(See page 11±60)
Page 1904 of 5135

110UC±01
A79148
SST
A79143
SST
11±78
±
FUEL COMMON RAIL ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DRAIN ENGINE COOLANT(See page 16±44)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
4.REMOVE RADIATOR RESERVE TANK ASSY(See page 16±50) 5. REMOVE FUEL INLET PIPE SUB±ASSY
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and the injection pump with vinyl tape to prevent dust from
being introduced.
(a) Using SST, remove the fuel inlet pipe from the commonrail.
SST 09023±12700
(b) Using SST, remove the fuel inlet pipe from the injection pump.
SST 09023±12700
6. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts and the 2 upper infection pipe clamps from the intake manifold.
(b) Using SST, remove the injection pipe from the common
rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or plas-
tic bag.
7. REMOVE INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
8. REMOVE INJECTION PIPE SUB±ASSY NO.3 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.