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.
Page 1905 of 5135
A79154
A79147
30 cm
(11.81 in.)
SST
±
FUEL COMMON RAIL ASSY(1CD±FTV)
11±79
AVENSIS REPAIR MANUAL (RM1018E)
9.REMOVE INJECTION PIPE SUB±ASSY NO.4
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
10.DISCONNECT FUEL HOSE NO.4
(a)Disconnect the fuel hose from the common rail.
11.REMOVE INTAKE MANIFOLD INSULATOR NO.1(See page 11±69)
12.REMOVE COMMON RAIL ASSY
(a)Disconnect the engine wire connector from the bracket.
(b)Remove the 2 bolts and the common rail.
13.INSTALL COMMON RAIL ASSY Torque: 43 N m (438 kgf cm, 32 ft lbf)
14.INSTALL INTAKE MANIFOLD INSULATOR NO.1(See page 11±69)
15. INSTALL INJECTION PIPE SUB±ASSY NO.1
NOTICE:
In case of having the common rail replaced, must re-
place the injection pipes, too.
When assembling the pipes, perform the operation
with the engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and vinyl tape from the common rail.
(b) Temporarily install the injection pipe.
Page 1906 of 5135
11±80
± FUELCOMMON RAIL ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Using SST, tighten the nut of the injection pipe to the com-
mon rail side.
SST 09023±12700
Torque:
42 Nm (428 kgfcm, 31 ftlbf) for a used pipe using SST
46 Nm (469 kgfcm, 34 ftlbf) for a used pipe not using
SST
31 Nm (316 kgfcm, 23 ftlbf) for a new pipe using SST
34 Nm (347 kgfcm, 25 ftlbf) for a new pipe not using
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(d) Using SST, tighten the nut of the injection pipe to the injec-
tor side.
SST 09023±12700
Torque:
42 Nm (428 kgfcm, 31 ftlbf) for a used pipe using SST
46 Nm (469 kgfcm, 34 ftlbf) for a used pipe not using
SST
31 Nm (316 kgfcm, 23 ftlbf) for a new pipe using SST
34 Nm (347 kgfcm, 25 ftlbf) for a new pipe not using
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e) Install the 2 upper injection pipe clamps with the 2 nuts.
Torque: 5.0 Nm (51 kgfcm, 44 in.lbf)
16. INSTALL INJECTION PIPE SUB±ASSY NO.2
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
17. INSTALL INJECTION PIPE SUB±ASSY NO.3
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
18. INSTALL INJECTION PIPE SUB±ASSY NO.4
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
Page 1907 of 5135
A79149
30 cm
(11.81 in.)
SST
±
FUEL COMMON RAIL ASSY(1CD±FTV)
11±81
AVENSIS REPAIR MANUAL (RM1018E)
19.INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:
In case of having the common rail replaced, must re-
place fuel inlet pipe, too.
When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a)Temporarily install the fuel inlet pipe.
(b)Using SST, tighten the nut of the fuel inlet pipe to the com-
mon rail side.
SST09023±12700
Torque:
42 Nm (428 kgf cm, 31 ft lbf) for a used pipe using SST
46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using
SST
31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST
34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
(c)Using SST, tighten the nut of the fuel inlet pipe to the injec-
tion pump side.
SST09023±12700
Torque:
42 Nm (428 kgf cm, 31 ft lbf) for a used pipe using SST
46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using
SST
31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST
34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
20.INSTALL RADIATOR RESERVE TANK ASSY(See page 16±50)
21. INSTALL ENGINE COVER NO.1 Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
22.ADD ENGINE COOLANT(See page 16±44)
23.CHECK FOR ENGINE COOLANT LEAKS(See page 16±37)
24.CHECK FOR FUEL LEAKS(See page 11±60)
