Page 4577 of 5135

A09656
A79144
A85755
11−48
−
FUEL INJECTOR ASSY (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
12. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
13. REMOVE NOZZLE LEAKAGE PIPE NO.2
(a) Disconnect the 2 fuel hoses from the nozzle leakage pipe No. 2.
(b) Remove the 2 bolts and nozzle leakage pipe No. 2. 14. REMOVE CYLINDER HEAD COVER SUB −ASSY
(a) Remove the 10 bolts and cylinder head cover.
15. REMOVE NOZZLE LEAKAGE PIPE ASSY
(a) Remove the bolt and 4 hollow screws, then remove the nozzle leakage pipe and 4 gaskets.
NOTICE:
When removing the nozzle leakage pipe, place a shop rag
under the pipe to protect the cylinder head from the fuel re-
maining inside the pipe.
16. REMOVE NOZZLE HOLDER CLAMP
(a) Remove the 4 bolts, 4 washers and 4 nozzle holder clamps.
17. REMOVE INJECTOR ASSY
HINT:
Each injector assembly has its own fuel injection characteristic. When replacing the injector assembly, store
them in the correct order so that they can be returned to the original locations when reassembling.
(a) Remove the 4 injectors from the cylinder head.
(b) Remove the O −rings and back −up rings from each injector.
(c) Remove the 4 nozzle seats from the cylinder head.
18. REGISTRATION OF INJECTOR COMPENSATION CODE (REPLACEMENT OF THE NEW INJECTORS) (See page 05 −277)
HINT:
Each injector assembly has characteristic fuel injecting behavior. When replacing the injector assembly,
store them in the correct order so that they can be returned to the original locations when reassembling.
Page 4578 of 5135

A79187
O−ring Back−up Ring
A92435
A85760
90_
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
11−49
AVENSIS Supplement (RM1045E)
19. INSTALL INJECTOR ASSY
(a) Install the 4 new nozzle seats to the cylinder head.
(b) Install new back−up rings and O−rings to each injector.
(c) Apply a light coat of engine oil to the O−rings on each in-
jector.
(d) Install the injector to the cylinder head.
NOTICE:
Fit the injectors to the nozzle seat.
(e) Install the nozzle holder clamp as shown in the illustration.
Tighten the camshaft bearing cap bolt by hand to fix the
nozzle holder clamp.
NOTICE:
SPay attention to the mounting orientation of the wash-
er.
SWhen temporarily attaching the nozzle holder clamp
and mounting bolt, be careful not to orient them at an
angle.
HINT:
Apply a light coat of engine oil to the threads of the nozzle hold-
er clamp bolts.
(f) Install the injection pipe No. 1, No. 2, No. 3 and No. 4, then
tighten the nuts by hand.
(g) Install new 4 gaskets and the leakage pipe No. 1. Tighten
the 4 hollow screws by hand.
(h) Tighten the 4 nozzle holder clamp bolts.
Torque: 27 Nm (270 kgfcm, 20 ftlbf)
(i) Remove the 4 injection pipes.
20. INSTALL NOZZLE LEAKAGE PIPE ASSY
(a) Install the nozzle leakage pipe and 4 new gaskets.
NOTICE:
When installing the gaskets, pay attention to the mounting
orientation. Install the gasket so that the joint of the gasket
comes within the range shown in the illustration.
(b) Apply a light coat of engine oil to the 4 hollow screws and
the bolt.
Page 4579 of 5135

A86430
New Gasket
Hollow Screw
SST
A09663
:Seal Packing
11
−50
−
FUEL INJECTOR ASSY (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(c) Tighten the 4 hollow screws and bolt by hand.
(d) Tighten the 4 hollow screws and bolt. Torque:
16 Nm (163 kgf cm, 12 ft lbf) for hollow screw
20 N m (204 kgf cm, 15 ft lbf) for flange bolt
NOTICE:
In any case, when the torque exceeds the upper limit, re-
place the leakage pipe hollow screw and gaskets with new
ones.
(e) Check that there are no leaks from the nozzle leakage
pipe connection.
(1) Apply a light coat of soapy water (any fluid to detect fuel leaks) to the nozzle leakage pipe connection.
(2) Using SST (a turbocharger pressure gauge), attach SST to the fuel return side of the nozzle leakage
pipe, then maintain 100 kPa (1.0 kgf/cm
2 , 14.5 psi)
of pressure for 60 seconds to check that there are
no bubbles from the pipe connection.
SST 09992 −00242
(3) After checking fuel leaks, wipe off soapy water from
the pipe connection.
21. INSTALL CYLINDER HEAD COVER SUB −ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head. Seal packing: Part No. 08826 −00080 or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the cylinder head cover with the 10 bolts. Torque: 13 N m (135 kgf cm, 9.8 ft lbf)
22. INSTALL NOZZLE LEAKAGE PIPE NO.2
(a) Install the nozzle leakage pipe No. 2 with the 2 bolts. Torque: 8.8 N m (90 kgf cm, 78 in. lbf)
(b) Connect the 2 fuel hoses.
23. INSTALL NOZZLE HOLDER SEAL
(a) Install new 4 nozzle holder seals.
24. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)
Page 4580 of 5135

A87959
SST (11.81 in.)30 cm
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
11−51
AVENSIS Supplement (RM1045E)
25. INSTALL INJECTION PIPE SUB−ASSY NO.1
NOTICE:
SIn case of replacing the injectors, the injection pipes
must be replaced, too.
SWhen assembling the pipes, perform the operation
with the engine cold under room temperature.
(a) Remove the vinyl or plastic bag from the injector and vinyl
tape from the common rail.
(b) Temporarily install the injection pipe.
(c) Using SST, tighten the nut of the injection pipe to the com-
mon rail.
SST 09023−12700
Torque:
31 Nm (316 kgfcm, 23 ftlbf) with SST
34 Nm (347 kgfcm, 25 ftlbf) without SST
HINT:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter the injection pipe is reassembled, check that the
used pipe has no deflection and is installed properly. If it
has deflection or could 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.
SST 09023−12700
Torque:
For used pipe:
36 Nm (372 kgfcm, 27 ftlbf) with SST
40 Nm (408 kgfcm, 30 ftlbf) without SST
For new pipe:
31 Nm (316 kgfcm, 23 ftlbf) with SST
34 Nm (347 kgfcm, 25 ftlbf) without SST
HINT:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter the injection pipe is reassembled, check that the
used pipe has no deflection and is installed properly. If it
has deflection or could not be installed properly, replace
the used pipe with a new pipe.
26. INSTALL INJECTION PIPE SUB−ASSY NO.2
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
27. INSTALL INJECTION PIPE SUB−ASSY NO.3
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
Page 4581 of 5135

A85632
A85631
SST
A85632
AA
B
A 11−52
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
28. INSTALL INJECTION PIPE SUB−ASSY NO.4
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
29. INSTALL FUEL PIPE NO.3
(a) Install 2 new gaskets, then temporarily install the bolt, 3
nuts and fuel pipe No. 3.
(b) Hold the hexagonal lobe of the exhaust fuel addition in-
jector assembly first. Using SST, tighten the nut of the fuel
pipe No. 3 to the injector side.
SST 09023−12700
Torque:
22 Nm (223 kgfcm, 16 ftlbf) with SST
24 Nm (240 kgfcm, 17 ftlbf) without SST
HINT:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter the injection pipe is reassembled, check that the
used pipe has no deflection and is installed properly. If it
has deflection or could not be installed properly, replace
the used pipe with a new pipe.
(c) Tighten the bolt and 3 nuts.
Torque:
5.0 Nm (51 kgfcm, 44 in.lbf) for bolt and nut A
27 Nm (275 kgfcm, 20 ftlbf) for nut B
(d) Install the fuel pipe insulator.
Page 4582 of 5135
A84387
2to7mm0 to 5 mm *2
(0 to 0.1969 in.)
(0.0787 to
0.2756 in.)0 to 2 mm *1
*1: Turbocharger Side
*2: Intercooler Side(0 to 0.0787 in.)
A93662
Turbocharger Side:
Intercooler Side:Upward
Front90_
Clamp
90_ Bolt
Clamp
Bolt
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
11−53
AVENSIS Supplement (RM1045E)
30. INSTALL AIR TUBE NO.1
(a) Install the air hose and hose clamps as shown in the il-
lustration.
(b) Tighten the hose clamps as shown in the illustration.
Torque: 6.0 Nm (61 kgfcm, 53 in.lbf)
(c) Install the air tube No. 1 with the 3 bolts and nut.
Torque: 25 Nm (255 kgfcm, 18 ftlbf)
31. INSTALL AIR CLEANER ASSY
Torque: 7.0 Nm (71 kgfcm, 62 in.lbf)
32. INSTALL ENGINE COVER SUB−ASSY NO.1
Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
33. INSTALL VACUUM RESERVOIR SUB−ASSY
Torque: 8.3 Nm (85 kgfcm, 73 in.lbf)
Page 4583 of 5135

11−54
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
34. CHECK FOR FUEL LEAKS
NOTICE:
Under the ACTIVE TEST mode, the fuel pressure increases. Take precautions to prevent fuel from
spraying on you or inside the engine compartment.
HINT:
During the ACTIVE TEST mode, engine speed goes high and combustion noise becomes loud.
(a) Check that there are no fuel leaks from any parts of the fuel system when the engine is not running.
HINT:
If fuel leakage could be found on specific parts, replace them with new parts.
(b) While cranking or when starting the engine, check that there is no leaks from any parts of the fuel sys-
tem.
HINT:
If fuel leakage could be found on specific parts, replace them with new parts.
(c) Disconnect the fuel hose from the common rail.
(d) While cranking the engine, check fuel leaks from the return pipe.
HINT:
If there is fuel leakage, replace the common rail.
(e) Connect the hand−held tester to the DLC3.
(f) Start the engine, then turn the hand−held tester ON.
(g) Select the FUEL LEAK test of the ACTIVE TEST mode on the hand−held tester.
(h) If you do not have the hand−held tester, depress the accelerator pedal quickly and fully to increase
the engine speed to its maximum, then keep it for 2 seconds. Repeat this operation several times.
(i) Check that there are no leaks from any parts of the fuel system.
NOTICE:
If the leakage from the return pipe is less than 10 cc (0.6 cu in.) in a minute, it is acceptable.
HINT:
If fuel leakage could be found on specific parts, replace them with new parts.
(j) Reconnect the fuel hose to the common rail.
Page 4584 of 5135
110U7−02
A85739
Radiator Support Opening Cover
Engine Cover Sub−assy No. 1
Vacuum Reservoir Sub−assy
Union to Connector Tube Hose
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
N·m (kgf·cm, ft·lbf)
: Specified torque
8.0 (82, 71 in.lbf)
8.3 (85, 73 in.lbf)
7.0 (71, 62 in.lbf)
Clip
Retainer
25 (255, 18)
Air Tube No. 1
25 (255, 18)
x5
x2
x3
25 (255, 18)
Mass Air Flow Meter
Connector
6.0 (61, 53 in.lbf)
6.0 (61, 53 in.lbf)
11−44
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
INJECTOR ASSY (1CD−FTV)(From September, 2003)
COMPONENTS