2005 TOYOTA AVENSIS fuel

A77894
A77891
A77892
A77893
Upper
Fuel Tank
Rear
Hose Clamp
A81617
Push 11±98
± FUELFUEL TANK ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
22. REMOVE FUEL TANK RETURN TUBE (1AZ±FSE
ENGINE TYPE)
(a) Unfasten the 5 claws and remove the fuel tank return tube
from the fuel tank.
23. REMOVE FUEL EVAPORATION TUBE SUB±ASSY
NO.2
(a) Unfasten the 4 claws and remove the fuel evaporation
tube from the fuel tank.
24. REMOVE FUEL TANK MAIN TUBE SUB±ASSY
(a) Unfasten the 4 claws and remove the fuel tank main tube
from the fuel tank.
25. INSTALL FUEL TANK MAIN TUBE SUB±ASSY
26. INSTALL FUEL EVAPORATION TUBE SUB±ASSY
NO.2
(a) Install the hose clamp as shown in the illustration.
27. INSTALL FUEL TANK RETURN TUBE (1AZ±FSE
ENGINE TYPE)
28. INSTALL FUEL TANK ASSY
Torque: 40 N
m (400 kgf
cm, 29 ft
lbf)
29. 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.

A81618
Push
2
1
Retainer
A77857
A78440
New Gasket
A77857
± FUELFUEL TANK ASSY (GASOLINE)
11±99
AVENSIS REPAIR MANUAL (RM1018E)
30. CONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a) Push in the fuel tube connector to the pipe until it makes
ºclickº sound, and then push up the retainer to the claws
lock.
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.
31. CONNECT FUEL TANK RETURN TUBE (1AZ±FSE
ENGINE TYPE)
32. CONNECT FUEL TANK TO FILLER PIPE HOSE
33. CONNECT BREATHER TUBE FUEL HOSE
34. INSTALL PARKING BRAKE CABLE ASSY NO.3
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
35. INSTALL PARKING BRAKE CABLE ASSY NO.2
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
36. INSTALL FUEL TANK PROTECTOR NO.1
Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
37. INSTALL EXHAUST PIPE ASSY CENTER
(1ZZ±FE/3ZZ±FE ENGINE TYPE)
(a) Compression spring inspection
(1) Using vernier calipers, measure the free length of
the compression spring.
Minimum length:
41.5 mm (1.634 in.) for front x manifold
38.5 mm (1.516 in.) for front x tail
If the free length is less than minimum, replace the compression
spring.
(b) Install each new gasket to the exhaust manifold and the
exhaust pipe front as shown in the illustration.
(c) Install the exhaust pipe front to the 2 exhaust pipe sup-
ports
(d) Tighten the 4 compression springs and 4 bolts.
Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
(e) Install the grommet. (w/o HID Sensor)
(f) Connect the heated oxygen sensor connector.
(g) Install the floor carpet with the 2 clips. (w/o HID Sensor)
38. INSTALL EXHAUST PIPE ASSY CENTER
(1AZ±FE/1AZ±FSE ENGINE TYPE)
(a) Compression spring inspection
(1) Using vernier calipers, measure the free length of
the compression spring.
Minimum length: 38.5 mm (1.516 in.)
If the free length is less than minimum, replace the compression
spring.

A78440
New Gasket
11±100
±
FUEL FUEL TANK ASSY(GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install a new gasket to the the exhaust pipe center (ex- haust pipe tail side) as shown in the illustration.
(c)Install a new gasket (exhaust pipe front side) and the ex-
haust pipe center to the 2 exhaust pipe supports.
(d)Tighten the 2 compression springs and 4 bolts. Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
39.ADD FUEL
40.INSTALL FUEL SUCTION W/PUMP & GAGE TUBE ASSY (See page 11±85) SST 09808±14010
41.CONNECT FUEL EVAPORATION TUBE SUB±ASSY NO.2 (See page 11±85)
42.CONNECT FUEL TANK MAIN TUBE SUB±ASSY (See page 11±85)
43.CONNECT FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE) (See page 11±85)
44. CHECK FOR FUEL LEAKS
HINT:

1ZZ±FE/3ZZ±FE: 11±5

1AZ±FE: 11±19

1AZ±FSE: 11±33
45. CHECK FOR EXHAUST GAS LEAKS
46.INSTALL FLOOR PANEL BRACE FRONT (See page 15±2)
47. INSTALL REAR FLOOR SERVICE HOLE COVER
48.INSTALL REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 72±32)
49. INSTALL FRONT FLOOR FOOTREST (W/O HID SENSOR)

110U6±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
± FUELFUEL TANK ASSY (GASOLINE)
11±89
AVENSIS REPAIR MANUAL (RM1018E)
FUEL TANK ASSY (GASOLINE)
COMPONENTS

A78517
N´m (kgf´cm, ft´lbf) : Specified torque

Non±reusable partRHD:
Front Floor Footrest 1ZZ±FE/3ZZ±FE:
Floor Carpet Assy FrontClip
Compression Spring
Exhaust Pipe
Gasket
Exhaust Pipe Assy Front
Floor Panel Brace Front
43 (440, 33)
30 (302, 22)

Exhaust Pipe
Gasket
Compression Spring
43 (440, 32)
Exhaust Pipe Assy Center
43 (440, 32)

Exhaust Pipe
Gasket
Floor Panel Brace Front
30 (302, 22)
Compression Spring
43 (440, 32)

Exhaust Pipe
Gasket
1AZ±FE:
Exhaust Pipe Assy Center
43 (440, 32)

Exhaust Pipe
Gasket
Floor Panel Brace Front
30 (302, 22)
Compression Spring
43 (440, 32)

Exhaust Pipe
Gasket
1AZ±FE (Leaded Gasoline)
1AZ±FSE:
w/o HID Sensor: 11±90
± FUELFUEL TANK ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)

A77881
Fuel Tank AssyFuel Hose No. 1Fuel Tank
to Filler Pipe Hose
Fuel Tank Band Sub±assy
No. 1
Fuel Tank Band Sub±assy
No. 1 LH
Fuel Tank Protector
No. 1
Parking Brake Cable Assy
No. 2
Parking Brake Cable Assy
No. 3
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
5.4 (54, 47 in.
lbf)x4
40 (400, 29)
40 (400, 29)
N´m (kgf´cm, ft´lbf) : Specified torque
± FUELFUEL TANK ASSY (GASOLINE)
11±91
AVENSIS REPAIR MANUAL (RM1018E)

A77882
1AZ±FSE:
Fuel Tank Return TubeFuel Evaporation Tube Sub±assy
No. 2
Fuel Tank Main Tube Sub±assy
Fuel Tank Assy
11±92
± FUELFUEL TANK ASSY (GASOLINE)
AVENSIS REPAIR MANUAL (RM1018E)

1306Z±01
A79155
A80093
A79158
±
INTAKE TURBOCHARGER SUB±ASSY(1CD±FTV)
13±11
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
2.DRAIN ENGINE COOLANT(See page 16±44)
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
5.REMOVE VACUUM RESERVOIR SUB±ASSY
(a)Disconnect the 2 vacuum hoses and the connector.
(b)Remove the 2 bolts and the vacuum reservoir.
6.REMOVE AIR CLEANER ASSY
(a)Disconnect the PCV hose and 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. 7.REMOVE INTERCOOLER AIR HOSE
(a)Remove the 3 bolts and nut, separate the air tube No.1.
(b)Loosen the hose clamp bolts and remove the air hoseNo.1.
8.REMOVE FUEL FILTER ASSY(See page 11±82) 9. SEPARATE HEATER PUMP ASSY (W/ COLD AREA)
(a) Remove the nut and disconnect the connector.
(b) Separate the heater pump.