Page 4593 of 5135
A88263
A88264
Torx Socket T40
A88265
(a)
(b)(b)(b)(b)(b)
A88266
(c)
(d)
(c)(c)
(c)
(d)(d)(d)
A79590
11−16
− FUELFUEL INJECTOR ASSY (2AZ−FSE)
AVENSIS Supplement (RM1045E)
17. REMOVE INTAKE MANIFOLD INSULATOR NO.2
(a) Remove the intake manifold insulator No. 2 from the cylin-
der block.
18. REMOVE NOZZLE HOLDER CLAMP
(a) Using a Torx socket T40, remove the 4 bolts, then remove
the 4 nozzle holder clamps.
HINT:
The nozzle holder clamp is installed with a bolt.
19. REMOVE FUEL DELIVERY PIPE SUB−ASSY
(a) Disconnect the fuel hose from the fuel pipe No. 2.
(b) Remove the 5 bolts, then remove the fuel delivery pipe to-
gether with the 4 fuel injectors.
(c) Remove the 4 gaskets from the cylinder head.
(d) Remove the 4 seals from the cylinder head.
20. REMOVE FUEL INJECTOR ASSY
(a) Pull out the 4 fuel injectors from the fuel delivery pipe.
NOTICE:
Be careful not to damage the sealing surface of the fuel de-
livery pipe when removing the fuel injector.
Page 4594 of 5135
A80297
E−ring
Fuel Injector
Back−up Ring No. 3
Fuel Injector
Back−up Ring No. 2
Fuel Injector
Back−up Ring No. 1O−ring
A79592
5_
− FUELFUEL INJECTOR ASSY (2AZ−FSE)
11−17
AVENSIS Supplement (RM1045E)
21. INSTALL FUEL INJECTOR ASSY
(a) Install new fuel injector back−up ring No. 1, No. 2, No. 3,
a new O−ring and a new E−ring to each fuel injector.
NOTICE:
SThere is a draft angle inside the back−up ring No. 1
and No. 2. Put the draft angle downward when instal-
ling those rings to the fuel injector.
SThe back−up ring No. 1 and No. 2 have a diagonal slit.
Pay attention to the splice of the slits after installing
them.
SAfter Installation of these 5 rings to the fuel injector,
check that there are no damages and foreign objects
on them.
(b) Apply a light coat of spindle oil or gasoline to the O−ring
on the fuel injector and the mounting hole on the fuel de-
livery pipe.
(c) Install the fuel injector to the fuel delivery pipe as shown
in the illustration.
NOTICE:
SBe careful not to damage the sealing surface of the
fuel delivery pipe when installing the injector.
SCheck that there are no damages and foreign objects
in the fuel injector mounting hole of the fuel delivery
pipe sub−assy.
SIn order to avoid any damage, be sure to apply fuel to
both the O−ring and the mounting hole before instal-
ling the fuel injector to the fuel delivery pipe.
Page 4595 of 5135
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 Nm (127 kgfcm, 9 ftlbf)
(c) Tighten the 5 bolts until they reach the specified torque to
secure the fuel delivery pipe.
Torque: 19 Nm (194 kgfcm, 14 ftlbf)
(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 Nm (210 kgfcm, 15 ftlbf) for surge tank stay No. 1 x cylinder block
9.8 Nm (100 kgfcm, 7 ftlbf) 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.
Page 4596 of 5135
A88257
12345
A88256
(i)
(j)
(i)
−
FUEL FUEL INJECTOR ASSY (2AZ −FSE)
11 −19
AVENSIS Supplement (RM1045E)
(g) Using a Torx socket E7, install and tighten the 2 stud bolts
to secure the intake manifold, intake air control valve and
gasket.
Torque: 9.5 N m (97 kgf cm, 84 in. lbf)
(h) In order to install the intake manifold to the cylinder head, tighten the 3 bolts and 2 nuts in the sequence shown in
the illustration.
Torque: 30 N m (306 kgf cm, 22 ft lbf)
(i) Connect the 2 vacuum hoses to the VSV as shown in the illustration.
(j) Connect the VSV connector.
(k) Install the ventilation hose No. 1 to the ventilation valve and intake manifold.
(l) Connect the union to connector tube hose to the brake booster.
27. INSTALL VACUUM SENSOR ASSY (LHD STEERING POSITION TYPE) Torque: 5.5 N m (56 kgf cm, 49 in. lbf)
28. INSTALL CHARCOAL CANISTER ASSY
29. INSTALL FUEL PUMP ASSY (See page 11 −24)
30. INSTALL FUEL PIPE SUB −ASSY NO.1 (See page 11 −24)
SST 09023 −12900
31. INSTALL FUEL HOSE
32. INSTALL FUEL TUBE SUB −ASSY (See page 11 −24)
SST 09617 −24011
33. INSTALL THROTTLE BODY ASSY (See page 10 −8)
34. INSTALL AIR CLEANER CAP SUB −ASSY (See page 10 −8)
35. CONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL) Torque: 5.4 N m (55 kgf cm, 48 in. lbf)
Page 4597 of 5135
11−20
−
FUEL FUEL INJECTOR ASSY (2AZ −FSE)
AVENSIS Supplement (RM1045E)
36. ADD ENGINE COOLANT (see page 16 −7)
37. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)
38. CHECK FOR FUEL LEAKS (See page 11 −4)
39. CHECK FOR ENGINE OIL LEAKS
40. INSTALL ENGINE COVER SUB −ASSY NO.1 (See page 10 −8)
41. INSTALL ENGINE ROOM COVER SIDE
42. INSTALL RADIATOR SUPPORT OPENING COVER
Page 4598 of 5135
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 2.85at 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 1.39at 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 3.0at 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.
Page 4599 of 5135
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.
Page 4600 of 5135
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.