2005 TOYOTA AVENSIS fuel pressure

A88259
(g)(h)
(g)
A88260
Intake Manifold Intake Manifold
Insulator No. 1
A88261
(d)
(b)
(c)
(a)(b)(b)(b)
A88262
− FUELFUEL INJECTOR ASSY (2AZ−FSE)
11−15
AVENSIS Supplement (RM1045E)
(g) Disconnect the 2 vacuum hoses from the intake air control
valve and pressure sensor.
(h) Disconnect the pressure sensor connector.
(i) Remove the intake air control valve and gasket from the
cylinder head.
(j) Remove the intake manifold insulator No. 1 from the in-
take manifold.
(k) Remove the intake manifold from the vehicle.
16. REMOVE SURGE TANK STAY NO.1
(a) Disconnect the fuel pressure sensor connector.
(b) Disconnect the 4 fuel injector connectors.
(c) Remove the nut.
(d) Remove the wiring harness clamp, then remove the en-
gine wire.
(e) Remove the 2 bolts, then remove the surge tank stay No.
1.

A88267
(a)
(b)
(b)(b)
(b)
(a)(a)(a)
A88268
Torx Socket T40
11−18
− FUELFUEL INJECTOR ASSY (2AZ−FSE)
AVENSIS Supplement (RM1045E)
22. INSTALL FUEL DELIVERY PIPE SUB−ASSY
(a) Install the 4 new seals to the cylinder head.
NOTICE:
Pay attention the mounting orientation of the seal.
(b) Install the 4 new gaskets to the cylinder head.
(c) Install the fuel delivery pipe together with the 4 fuel injec-
tors to the cylinder head.
NOTICE:
SRemove any carbon from the tip of the fuel injector if
necessary.
SDo not give any physical impact on the tip because
the fuel injector tip is sensitive.
SIf you drop the fuel injector by mistake, replace it with
a new one.
SCheck that there are no damages and foreign objects
on the fuel injector mounting area of the cylinder
head.
(d) Temporarily install the fuel delivery pipe with the 5 bolts.
23. INSTALL NOZZLE HOLDER CLAMP
(a) Align the keyway of the fuel injector with the nozzle holder
clamp, then fit them.
(b) Using a Torx socket T40, install the 4 nozzle holder
clamps with the 4 bolts.
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.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
(d) Connect the fuel hose to the fuel pipe No. 2.
24. INSTALL INTAKE MANIFOLD INSULATOR NO.2
25. INSTALL SURGE TANK STAY NO.1
Torque:
21 N
m (210 kgf
cm, 15 ft
lbf) for surge tank stay No. 1 x cylinder block
9.8 N
m (100 kgf
cm, 7 ft
lbf) for surge tank stay No. 1 x engine wire
26. INSTALL INTAKE MANIFOLD
(a) Install a new gasket to the intake manifold.
(b) Temporarily install the intake manifold to the cylinder
head.
(c) Install the intake manifold insulator No. 1 to the intake
manifold.
(d) Temporarily install the intake air control valve and a new
gasket between the intake manifold and cylinder head,
then check that the stud bolt holes are aligned.
(e) Connect the 2 vacuum hoses to the intake air control
valve and pressure sensor.
(f) Connect the pressure sensor connector.

1111 2−01
A84684
Ohmmeter
A84687
Ohmmeter
A88285
Ohmmeter
A88300Battery
− FUELFUEL SYSTEM (2AZ−FSE)
11−7
AVENSIS Supplement (RM1045E)
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 injec-
tion volume.
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Standard:
Tester ConnectionSpecified Condition
1−22.55 to 2.85
at 20_C (68_F)
If the resistance is not as specified, replace the fuel injector.
2. INSPECT FUEL PUMP ASSY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Standard:
Tester ConnectionSpecified Condition
1−21.19 to 1.39
at 20_C (68_F)
If the resistance is not as specified, replace the fuel pump.
3. INSPECT FUEL PUMP ASSY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Standard:
Tester ConnectionSpecified Condition
4−50.2 to 3.0
at 20_C (68_F)
If the resistance is not as specified, replace the fuel pump.
(b) Check the operation.
(1) Apply battery voltage across the terminals. Check
that the fuel pump operates.
NOTICE:
SThese tests must be performed quickly (within 10 se-
conds) to prevent burnout of the coil.
SKeep fuel pump as far away from the battery as pos-
sible.
SAlways do the switching at the battery side.
If the operate is not as specified, replace the fuel pump.

11111−01
Fuel Tube Connector
A50710
A60083
Fuel Pipe
Clamp No.1
A
A
B12941
11−4
−
FUEL FUEL SYSTEM (2AZ −FSE)
AVENSIS Supplement (RM1045E)
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 −1) .
(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) Detach the fuel tube clamp from the fuel tube connector.
(f) Disconnect the fuel tube connector from the fuel pipe while pinching portion A with your fingers as shown in the
illustration.
CAUTION:
SDo not disconnect the fuel tube connector (quick
type) until you have discharged the fuel system pres-
sure and taken appropriate steps to prevent fuel spill-
age.
SThere may be some pressure remained in the fuel
lines after discharging the pressure.
Take precautions to prevent fuel from spraying on
you, your clothing or inside the engine compartment.

No.1 Fuel Pipe
Fuel Tube Connector
SST
(Clip)
SST (T joint)SST
SST
(Hose)
B12975
− FUELFUEL SYSTEM (2AZ−FSE)
11−5
AVENSIS Supplement (RM1045E)
(g) Install SST (pressure gauge) and the 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−held 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 hose connections, fuel pump,
fuel filter and 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, pressure
regulator and/or fuel injectors.
(q) After checking the fuel pressure, disconnect the negative
(−) battery cable and carefully remove SST and the fuel
tube connector to prevent gasoline splash.
(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.

A88284Battery
A13269B12608
A91714
Hand−held Tester
11 −6
−
FUEL FUEL SYSTEM (2AZ −FSE)
AVENSIS Supplement (RM1045E)
(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 engine cover No. 1 (see page 10 −8) .
(b) Start the engine.
(c) Using a sound scope, hear the operating sound of the pump.
If there is no sound, replace the fuel pump.
(d) Stop the engine.
(e) Reinstall the engine cover No. 1 (see page 10 −8) .
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.

100LZ−01
A88269
(a)
(b)
A78436
10 _
10 _ Upper
Engine
Front
10
−16
−
ENGINE CONTROL SYSTEM KNOCK SENSOR (2AZ−FSE)
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. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 10 −8)
6. DRAIN ENGINE COOLANT (See page 16 −7)
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 (See page 11 −13)
14. REMOVE VACUUM SENSOR ASSY (LHD STEERING POSITION TYPE) (See page 11 −13)
15. REMOVE INTAKE MANIFOLD (See page 11 −4)
16. REMOVE SURGE TANK STAY NO.1 (See page 11 −13)
17. REMOVE INTAKE MANIFOLD INSULATOR NO.2 (See page 11 −13)
18. REMOVE KNOCK SENSOR
(a) Disconnect the knock sensor connector.
(b) Remove the nut, then remove the knock sensor.
19. INSTALL KNOCK SENSOR
(a) Install the knock sensor with the nut as shown in the il- lustration.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(b) Connect the knock sensor connector.
20. INSTALL INTAKE MANIFOLD INSULATOR NO.2
21. INSTALL SURGE TANK STAY NO.1 ( See page 11 −13)
22. INSTALL INTAKE MANIFOLD (See page 11 −13)
23. INSTALL VACUUM SENSOR ASSY (LHD STEERING POSITION TYPE) (See page 11 −13)
24. INSTALL CHARCOAL CANISTER ASSY

141NM−01
14 −166−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE ENGINE UNDER COVER LH
3. REMOVE ENGINE UNDER COVER SUB −ASSY NO.1
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE RADIATOR SUPPORT OPENING COVER
6. REMOVE ENGINE ROOM COVER SIDE
7. DRAIN ENGINE COOLANT (See page 16 −19)
8. DRAIN ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
9. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
10. REMOVE VACUUM RESERVOIR SUB −ASSY (See page 14 −108)
11. REMOVE AIR CLEANER ASSY (See page 14 −108)
12. REMOVE BATTERY
13. REMOVE AIR TUBE NO.2 (See page 14 −108)
14. REMOVE AIR TUBE NO.1 (See page 14 −108)
15. REMOVE INJECTOR DRIVER (See page 14 −108)
16. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See Pub. No. RM1018E on page 14 −269)
17. REMOVE GENERATOR V BELT (See Pub. No. RM1018E on page 14 −269)
18. SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14 −138)
19. DISCONNECT ENGINE WIRE (See page 14 −138)
20. DISCONNECT VACUUM HOSE (See page 14 −108)
21. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSY(See page 14 −108)
22. REMOVE ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
23. REMOVE CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05031)
24. REMOVE IDLER PULLEY SUB −ASSY (See page 14 −138)
25. REMOVE TIMING BELT NO.2 COVER (See page 14 −138)
26. REMOVE TIMING BELT NO.1 COVER (See page 14 −138)
27. REMOVE TIMING BELT GUIDE
28. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
29. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
30. REMOVE TIMING CHAIN COVER PLATE (See page 14 −138)
31. REMOVE TIMING BELT (See page 14 −138)
HINT:
If reusing the timing belt, draw an arrow on the timing belt which indicates the engine revolution direction
and put match marks on the pulleys and timing belt.
32. REMOVE FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)
33. REMOVE HEATER PUMP ASSY (W/ COLD AREA) (See page 13 −12)
34. REMOVE HEATER BRACKET (W/ COLD AREA) (See page 13 −12)
35. REMOVE FLOOR PANEL BRACE FRONT (See page 15 −6)
36. REMOVE EXHAUST PIPE ASSY FRONT (See page 15 −6)
37. REMOVE EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13 −12)
38. DISCONNECT RADIATOR HOSE INLET
39. DISCONNECT HEATER INLET WATER HOSE
40. DISCONNECT HEATER OUTLET WATER HOSE
41. DISCONNECT FUEL PIPE TO FUEL TUBE FUEL HOSE
42. DISCONNECT OIL COOLER HOSE