Common Rail Assy (1Cd-Ftv) : Components

1176
FUEL COMMON RAIL ASSY (1CDFTV)
COMMON RAIL ASSY (1CDFTV)

110UB01
COMPONENTS
Clip
Ratainer
8.0 (82, 71 in.Vlbf)
Radiator Support Opening Cover
Engine Cover No. 1
6.0 (61, 53 in.Vlbf)
Radiator Reserve Tank Assy
Nm (kgfcm, ftlbf) : Specified torque

A79437
AVENSIS REPAIR MANUAL (RM1018E)
1177
* 31 (316, 23) 34 (347, 25) 5.0 (51, 44 in.Vlbf)
Injection Pipe Clamp No. 2 z Fuel Inlet Pipe Subassy

* 31 (316, 23) 34 (347, 25)
z Injection Pipe Subassy
* 31 (316, 23) 34 (347, 25)
Common Rail Assy
Intake Manifold Insulator No. 1
5.0 (51, 44 in.Vlbf) 43 (438, 32)
Fuel Hose No. 4
Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part * Use SST

A79438
1178
110UC01
REPLACEMENT
1. 2. 3. (a) 4. DRAIN ENGINE COOLANT (See page 1644) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE COVER NO.1 Remove the 5 nuts and the engine cover. REMOVE RADIATOR RESERVE TANK ASSY (See page 1650)
SST
A79148
5. REMOVE FUEL INLET PIPE SUBASSY 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 common rail. SST 0902312700 (b) Using SST, remove the fuel inlet pipe from the injection pump. SST 0902312700
6. (a) (b)
SST
(c)
A79143
(d)
7.
REMOVE INJECTION PIPE SUBASSY SST 0902312700
REMOVE INJECTION PIPE SUBASSY NO.1 Remove the 2 nuts and the 2 upper infection pipe clamps from the intake manifold. Using SST, remove the injection pipe from the common rail side. SST 0902312700 Using SST, remove the injection pipe from the injector side. SST 0902312700 After removing the fuel pipe, to prevent dust or foreign objects from being introduced, cover the common rail with vinyl tape and protect the injector inlet with a vinyl or plastic bag. NO.2
HINT: Perform the same procedures as injection pipe No. 1. 8. REMOVE INJECTION PIPE SUBASSY NO.3 SST 0902312700 HINT: Perform the same procedures as injection pipe No. 1.
1179
9.
REMOVE INJECTION PIPE SUBASSY NO.4 SST 0902312700
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 1169)
12. (a) (b)
REMOVE COMMON RAIL ASSY Disconnect the engine wire connector from the bracket. Remove the 2 bolts and the common rail.
A79154
13. 14.
INSTALL COMMON RAIL ASSY Torque: 43 NVm (438 kgfVcm, 32 ftVlbf) INSTALL INTAKE MANIFOLD INSULATOR NO.1 (See page 1169)
30 cm (11.81 in.)
SST
A79147
15. INSTALL INJECTION PIPE SUBASSY NO.1 NOTICE: S In case of having the common rail replaced, must replace the injection pipes, too. S 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.
1180
(c)
Using SST, tighten the nut of the injection pipe to the common rail side. SST 0902312700 Torque: 42 NVm (428 kgfVcm, 31 ftVlbf) for a used pipe using SST 46 NVm (469 kgfVcm, 34 ftVlbf) for a used pipe not using SST 31 NVm (316 kgfVcm, 23 ftVlbf) for a new pipe using SST 34 NVm (347 kgfVcm, 25 ftVlbf) for a new pipe not using SST Use a torque wrench with a fulcrum length of 30 cm (11.81 in.) Check if the used pipe has deflection or is installed properly after injection pipe is reassembled. If there is deflection or if it can not be installed properly, replace the used pipe with a new pipe. Using SST, tighten the nut of the injection pipe to the injector side. SST 0902312700 Torque: 42 NVm (428 kgfVcm, 31 ftVlbf) for a used pipe using SST 46 NVm (469 kgfVcm, 34 ftVlbf) for a used pipe not using SST 31 NVm (316 kgfVcm, 23 ftVlbf) for a new pipe using SST 34 NVm (347 kgfVcm, 25 ftVlbf) for a new pipe not using SST
HINT:
S S
(d)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.) S Check if the used pipe has deflection or is installed properly after injection pipe is reassembled. If there is deflection 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 NVm (51 kgfVcm, 44 in.Vlbf) INSTALL INJECTION PIPE SUBASSY NO.2 SST 0902312700
S
16.
HINT: Perform the same procedures as injection pipe No. 1. 17. INSTALL INJECTION PIPE SUBASSY NO.3 SST 0902312700 HINT: Perform the same procedures as injection pipe No. 1. 18. INSTALL INJECTION PIPE SUBASSY NO.4 SST 0902312700 HINT: Perform the same procedures as injection pipe No. 1.
1181
20. 21. 22. 23. 24.
19. INSTALL FUEL INLET PIPE SUBASSY NOTICE: 30 cm S In case of having the common rail replaced, must re(11.81 in.) place fuel inlet pipe, too. S When assembling the pipe, perform the operation with the engine cold under room temperature. SST (a) Temporarily install the fuel inlet pipe. (b) Using SST, tighten the nut of the fuel inlet pipe to the common rail side. A79149 SST 0902312700 Torque: 42 NVm (428 kgfVcm, 31 ftVlbf) for a used pipe using SST 46 NVm (469 kgfVcm, 34 ftVlbf) for a used pipe not using SST 31 NVm (316 kgfVcm, 23 ftVlbf) for a new pipe using SST 34 NVm (347 kgfVcm, 25 ftVlbf) for a new pipe not using SST HINT: S Use a torque wrench with a fulcrum length of 30 cm (11.81 in.) S Check if the used pipe has deflection or is installed properly 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 injection pump side. SST 0902312700 Torque: 42 NVm (428 kgfVcm, 31 ftVlbf) for a used pipe using SST 46 NVm (469 kgfVcm, 34 ftVlbf) for a used pipe not using SST 31 NVm (316 kgfVcm, 23 ftVlbf) for a new pipe using SST 34 NVm (347 kgfVcm, 25 ftVlbf) for a new pipe not using SST HINT: S Use a torque wrench with a fulcrum length of 30 cm (11.81 in.) S Check if the used pipe has deflection or is installed properly 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. INSTALL RADIATOR RESERVE TANK ASSY (See page 1650) INSTALL ENGINE COVER NO.1 Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf) ADD ENGINE COOLANT (See page 1644) CHECK FOR ENGINE COOLANT LEAKS (See page 1637) CHECK FOR FUEL LEAKS (See page 1160)
1182
FUEL FUEL FILTER ASSY (1CDFTV)
FUEL FILTER ASSY (1CDFTV)

110UD01
REPLACEMENT
1. (a) (b) (c) (d) 2. (a) (b) (c) (d) 3. (a) REMOVE AIR CLEANER ASSY Disconnect the connector. Remove the air cleaner cap with the air cleaner hose. Remove the air cleaner filter element. Remove the 3 bolts and the air cleaner case. REMOVE FUEL FILTER ASSY Disconnect the 2 fuel hose from the fuel filter. (STD or COLD) Disconnect the 3 fuel hose from the fuel filter. (W/ ADDTIONAL HEATER) Disconnect the 2 connectors. Remove the 2 bolts and the fuel filter. DRAIN FUEL 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.
A79188
5. (a)
REMOVE FUEL FILTER ELEMENT Using SST, remove the fuel filter element. SST 0922864030
SST
A80091
6. (a) (b) (c) (d)
INSTALL FUEL FILTER ELEMENT Check and clean the fuel filter installation surface. Apply fuel to a gasket of a new fuel filter element. Lightly screw the fuel filter element into place, and tighten it until the gasket comes into contact with the seat. Tighten it additional 3/4 turn by hand.
A79190
1183
FUEL FUEL FILTER ASSY (1CDFTV)
7. (a) (b) (c) 8. 9. 10.
INSTALL LEVEL WARNING SWITCH Install a new Oring to the level warning switch. Apply fuel to the Oring of the level warning switch. Install the level warning switch to the fuel filter by hand. INSTALL FUEL FILTER ASSY Torque: 18 NVm (178 kgfVcm, 13 ftVlbf) INSTALL AIR CLEANER ASSY Torque: 7.0 NVm (71 kgfVcm, 62 in.Vlbf) CHECK FOR FUEL LEAKS (See page 1160)
1124
FUEL FUEL INJECTOR ASSY (1AZFE)
FUEL INJECTOR ASSY (1AZFE)

110U001
COMPONENTS
7.0 (71, 62 in.Vlbf)
Engine Cover Subassy No. 1 Fuel Vapor Feed Hose VSV Connector
Mass Air Flow Meter Connector Air Cleaner Cap Subassy
Fuel Vapor Feed Hose No. 2

A79730
1125
z Fuel Injector Oring Fuel Injector Assy
Fuel Injector Connector
20 (204, 15)
Fuel Delivery Pipe Subassy
EFI Fuel Pipe Clamp Delivery Pipe No. 1 Spacer z Injector Vibration Insulator
Fuel Tube Subassy
Ventilation Hose No. 2
Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part

A77907
1126
110U101
REPLACEMENT
1. 2. 3. DISCHARGE FUEL SYSTEM PRESSURE (See page 1115) REMOVE ENGINE COVER SUBASSY NO.1 (See page 1026) REMOVE AIR CLEANER CAP SUBASSY (See page 1026) DISCONNECT FUEL TUBE SUBASSY Remove the fuel pipe clamp. Using SST, disconnect the fuel tube. SST 0926821010 (1) Assemble SST to the connection of the fuel tube as shown in the illustration. (2) Turn SST, align the retainers inside the connector with SST into the connector. (3) Push in the SST and the connector together towards the fuel tube assembly. NOTICE: S Check if there is any dirt or mud on the pipe and around the connector before disconnecting them and remove the dirt as necessary. S Do not bent and twist the nylon tube. S When the connector and pipe are stuck, push and pull the connector to free. Pull the connector out carefully. S Prevent the disconnected pipe and connector from being damaged and foreign objects from being introduced, cover with a vinyl or plastic bag. 4. (a) (b)
Retainer (at 4 places) Fuel Pipe Clamp
Turn SST
Insert
A77908
Oring Retainer
Pipe
Nylon Tube
Housing
A76220
5. (a)
REMOVE FUEL DELIVERY PIPE SUBASSY Disconnect the ventilation hose.
A77909
1127
(b) (c)
Remove the 2 wire harness clamps. Disconnect the 4 fuel injector connectors.
(b) (b) (c) (c) (c)
(c)
A77910
(d)
Remove the 2 bolts, and then remove the fuel delivery pipe together with the 4 fuel injectors. NOTICE: Be careful not to drop the fuel injectors when removing the delivery pipe.
A78437
Delivery Pipe No. 1 Spacer
(e)
Remove the 2 delivery pipe No. 1 spacers and the 4 insulators from the cylinder head.
Insulator
A77911
6. (a)
REMOVE FUEL INJECTOR ASSY Pull out the 4 fuel injectors.
A77912
7. (a)
INSTALL FUEL INJECTOR ASSY Apply a light coat of spindle oil or gasoline to new Orings and install them to each fuel injector.
New Oring
A78481
1128
(b)
Turn Push
Apply a light coat of spindle oil or gasoline on the place where a fuel delivery pipe contacts the Oring. (c) Push the fuel injector while twisting it back and forth to install it to the fuel delivery pipe. NOTICE: S Be careful not to twist the Oring. S After installing the fuel injectors, check that they turn smoothly. If not, reinstall it with a new Oring.
A77913
8. (a)
Turn
A77914
INSTALL FUEL DELIVERY PIPE SUBASSY Install 4 new insulators and the 2 delivery pipe No. 1 spacers to the cylinder head. (b) Place the fuel delivery pipe and the 4 fuel injectors together to the cylinder head. NOTICE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe. (c) Temporarily install 2 bolts which are used to secure the fuel delivery pipe to the cylinder head. (d) Check that the fuel injectors rotate smoothly. If the fuel injectors do not rotate smoothly, the probable cause is incorrect installation of Oring. Replace with the Oring. (e) Tighten the 2 bolts. Torque: 20 NVm (204 kgfVcm, 15 ftVlbf) (f) Connect the 4 fuel injector connectors. (g) Install the 2 wire harness clamps. (h) Connect the ventilation hose.
Fuel Pipe Clamp
Push
A81621
CONNECT FUEL TUBE SUBASSY Push in the connector to the pipe until it makes click sound. NOTICE: S Check if there is any damage or foreign objects on the connected part. S After connecting, check if the connector and the pipe are securely connected by pulling on them. (b) Install the fuel pipe clamp.
9. (a)
10. 11. 12.
INSTALL AIR CLEANER CAP SUBASSY CHECK FOR FUEL LEAKS (See page 1119) INSTALL ENGINE COVER SUBASSY NO.1 (See page 1026)
1137
FUEL FUEL INJECTOR ASSY (1AZFSE)
FUEL INJECTOR ASSY (1AZFSE)

110TC01
COMPONENTS
Clip x2
Engine Room Cover Side
x4
Clip Retainer Radiator Support Opening Cover
7.0 (71, 62 in.Vlbf)
Engine Cover Subassy No. 1 Fuel Vapor Feed Hose

1.5 (15, 13 in.Vlbf)
VSV Connector
Mass Air Flow Meter Connector
Air Cleaner Cap Subassy

A78507
1138
Throttle Motor Connector
Throttle Body Assy x4
9.0 (90, 80 in.Vlbf)
z Throttle Body Gasket Water Bypass Hose No. 1 Water Bypass Hose No. 2
x4
Throttle Body Bracket
21 (210, 15)
Ground Terminal
8.4 (86, 74 in.Vlbf)
Wire Harness Protector
8.4 (86, 74 in.Vlbf)

A78508
1139
Fuel Tube Subassy z Gasket
Fuel Pipe Clamp
z Gasket
25 (255, 18) 33 (331, 24)
z Fuel Pump Insulator
Fuel Pump Assy

30 (306, 22)
Fuel Pressure Pulsation Damper Assy
Fuel Pipe Subassy No. 1

9.0 (92, 80 in.Vlbf)
Fuel Hose
z Fuel Injector Backup Ring No. 1 z Fuel Injector Backup Ring No. 2 z Oring z Fuel Injector Backup Ring No. 3
38 (388, 28 )
Engine Cover Bracket

A79577
1140
30 (306, 22)
Union to Connector Tube Hose

30 (306, 22)
Vacuum Hose
Intake Manifold
x2 z Gasket Intake Air Control Valve Assy z Gasket

9.5 (97, 84 in.Vlbf) 9.8 (100, 7) 30 (306, 22)

21 (210, 15)
Surge Tank Stay No. 1
38 (388, 28)
Engine Cover Bracket Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part

Charcoal Canister Assy
A79597
1141
z Ering z Oring z Fuel Injector Backup Ring No. 1
z Fuel Injector Backup Ring No. 3 z Fuel Injector Backup Ring No. 2
z Gasket
Injector Assy z Fuel Injector Seal

13 (127, 9)
Fuel Delivery Pipe Subassy Nozzle Holder Clamp
x5
19 (194, 14)

A79598
1110
FUEL FUEL INJECTOR ASSY (1ZZFE/3ZZFE)
FUEL INJECTOR ASSY (1ZZFE/3ZZFE)

110TY01
COMPONENTS
1ZZFE:
z Fuel Injector ORing Fuel Injector Assy 3ZZFE: Clip

7.0 (71, 62 in.lbf)
z Fuel Injector ORing z Fuel Injector Grommet Fuel Injector Assy
19 (189, 14)
Cylinder Head Cover No. 2 Fuel Pipe Clamp No. 2 Fuel Delivery Pipe Subassy Fuel Tube Subassy
z Injector Vibration Insulator

9.0 (91, 80 in.lbf)
No. 1 Spacer
Ventilation Hose Fuel Injector Connector

A78470
1111
110TZ01
REPLACEMENT
1. 2. DISCHARGE FUEL SYSTEM PRESSURE (See page 111) REMOVE CYLINDER HEAD COVER NO.2 (See page 109)
Retainer (at 4 places) Fuel Pipe Clamp
Turn SST
Insert
A78471
SEPARATE FUEL TUBE SUBASSY Remove the fuel pipe clamp. Using SST, disconnect the fuel tube. SST 0926821010 (1) Assemble SST to the connection of the fuel tube as shown in the illustration. (2) Turn SST, align the retainers inside the connector with SST into the connector. (3) Push in the SST and the connector together towards the fuel tube assembly. NOTICE: S Check if there is any dirt or mud on the pipe and around the connector before disconnecting them and remove the dirt as necessary. S Do not bent and twist the nylon tube. S When the connector and pipe are stuck, push and pull the connector to free. Pull the connector out carefully. S Prevent the disconnected pipe and connector from being damaged and foreign objects from being introduced, cover with a vinyl or plastic bag.
3. (a) (b)
Oring Retainer
Pipe
Nylon Tube
Housing
A76220
4. (a)
REMOVE FUEL DELIVERY PIPE SUBASSY Disconnect the ventilation hose.
A78472
1112
(a)
(a)
(b) (c)
(a) (a)
Disconnect the 4 fuel injector connectors. Remove the 3 wire harness clamps.
(b) (b) (b)

A78473
(d)
Remove the 3 bolts, and then remove the fuel delivery pipe together with the 4 fuel injectors. NOTICE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
A78480
(e)
Delivery Pipe No. 1 spacer
Remove the 2 delivery pipe No. 1 spacers and the 4 insulators from the cylinder head.
Insulator
A78475
5. (a)
REMOVE FUEL INJECTOR ASSY Pull out the 4 fuel injectors from the fuel delivery pipe.
A78476
1113
1ZZFE:
6. (a) (b)
INSTALL FUEL INJECTOR ASSY Install new grommets to each fuel injector. (3ZZFE) Apply a light coat of spindle oil or gasoline to new Orings, and install them to each fuel injector.
New Oring
A78477
3ZZFE:
New Oring New Grommet A78478
(c)
Turn Push
Apply a light coat of spindle oil or gasoline on the place where the fuel delivery pipe contacts the Oring. (d) Push the fuel injector while twisting it back and forth to install it to the fuel delivery pipe. NOTICE: S Be careful not to twist the Oring. S After installing the fuel injectors, check that they turn smoothly. If not, reinstall it with a new Oring.
A78479
A A
7. (a)
Turn B
A78474
INSTALL FUEL DELIVERY PIPE SUBASSY Instal 4 new insulators and the 2 delivery pipe No. 1 spacers to the cylinder head. (b) Place the fuel delivery pipe and 4 fuel injectors together to the cylinder head. NOTICE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe. (c) Temporarily install 3 bolts which are used to secure the fuel delivery pipe to the cylinder head. (d) Check that the fuel injectors rotate smoothly. If fuel injectors do not rotate smoothly, the probable cause is incorrect installation of Oring. Replace with the Oring. (e) Tighten the 3 bolts. Torque: 19 NVm (194 kgfVcm, 14 ftVlbf) for bolt A 9.0 NVm (92 kgfVcm, 80 in.Vlbf) for bolt B (f) Install the 3 wire harness clamps. (g) Connect the 4 fuel injector connectors. (h) Connect the ventilation hose.
1114
Fuel Pipe Clamp Push
8. (a)
A81613
CONNECT FUEL TUBE SUBASSY Push in the connector to the pipe until it makes click sound. NOTICE: S Check if there is any damage or foreign objects on the connected part. S After connecting, check if the connector and the pipe are securely connected by pulling on them. (b) Install the fuel pipe clamp.
9. 10.
CHECK FOR FUEL LEAKS (See page 115) INSTALL CYLINDER HEAD COVER NO.2 (See page 109)
FUEL
FUEL PRESSURE PULSATION DAMPER ASSY (1AZFE)
1129
FUEL PRESSURE PULSATION DAMPER ASSY (1AZFE)

110U201
REPLACEMENT
1. 2. 3. 4. DISCHARGE FUEL SYSTEM PRESSURE (See page 1115) REMOVE ENGINE COVER SUBASSY NO.1 (See page 1026) REMOVE AIR CLEANER CAP SUBASSY (See page 1026) DISCONNECT FUEL TUBE SUBASSY (See page 1126) SST 0926821010
5. (a)
REMOVE FUEL PRESSURE PULSATION DAMPER ASSY Remove the 2 bolts, and then remove the fuel pressure pulsation damper.
A77915
6. (a) (b) 7. 8. 9. 10.
INSTALL FUEL PRESSURE PULSATION DAMPER ASSY Apply a light coat of spindle oil or gasoline to a new Oring, and install it to the fuel pressure pulsation damper. Install the fuel pressure pulsation damper with the 2 bolts. Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf) CONNECT FUEL TUBE SUBASSY (See page 1126) INSTALL AIR CLEANER CAP SUBASSY CHECK FOR FUEL LEAKS (See page 1119) INSTALL ENGINE COVER SUBASSY NO.1 (See page 1026)
1149
FUEL FUEL PUMP ASSY (1AZFSE)
FUEL PUMP ASSY (1AZFSE)

110TA01
COMPONENTS
Clip x2
x4
Clip Retainer Radiator Support Opening Cover
7.0 (71, 62 in.Vlbf)
Engine Cover Subassy No. 1 Fuel Vapor Feed Hose

1.5 (15, 13 in.Vlbf)
VSV Connector
Mass Air Flow Meter Connector
Air Cleaner Cap Subassy

A78507
1150
Throttle Motor Connector
Throttle Body Assy x4
9.0 (90, 80 in.Vlbf)
z Throttle Body Gasket Water Bypass Hose No. 1 Water Bypass Hose No. 2
x4
Throttle Body Bracket
21 (210, 15)
Ground Terminal
8.4 (86, 74 in.Vlbf)
Wire Harness Protector
8.4 (86, 74 in.Vlbf)

A78508
1151
Fuel Tube Subassy z Gasket
Fuel Pipe Clamp
z Gasket
25 (255, 18) 33 (331, 24)
z Fuel Pump Insulator
Fuel Pump Assy

30 (306, 22)
Fuel Pressure Pulsation Damper Assy
Fuel pipe Subassy No. 1

9.0 (92, 80 in.Vlbf)
Fuel Hose
z Fuel Injector Backup Ring No. 1 z Fuel Injector Backup Ring No. 2 z Oring z Fuel Injector Backup Ring No. 3
38 (388, 28 )
Engine Cover Bracket

A79577
1152
110TB01
REPLACEMENT
1. 2. 3. 4. DISCHARGE FUEL SYSTEM PRESSURE (See page 1130) REMOVE RADIATOR SUPPORT OPENING COVER (See page 1816) REMOVE ENGINE COVER SUBASSY NO.1 (See page 1044) REMOVE AIR CLEANER CAP SUBASSY (See page 1044)
5. (a)
REMOVE ENGINE COVER BRACKET Remove the bolt and the engine cover bracket.
A79569
6.
SST
(a) (b)
REMOVE FUEL PRESSURE PULSATION DAMPER ASSY Disconnect the fuel tube subassy. (See page 1130) Using SST, remove the fuel pressure pulsation damper assy, the fuel tube subassy and the 2 gasket. SST 0961724011
A79570
7. (a)
REMOVE FUEL PIPE SUBASSY NO.1 Remove the fuel hose.
A79571
(b)
Clamp the union bolt on the fuel pump assy with a 21 mm wrench and remove the fuel pipe subassy No. 1 from the fuel pump assy using a 19 mm unionnut wrench. NOTICE: Do not loosen the union bolt on the fuel pump assy. If it become loose, replace the fuel pump assy with new fuel pump assy.
A79572
1153
(c)
Remove the 2 bolts first, then remove the fuel pipe sub assy No. 1 from the fuel delivery pipe subassy. NOTICE: Be careful not to damage both the sealing surfaces of the fuel delivery pipe and the fuel pump when removing the fuel pipe No.1.
A79573
8. (a) (b) (c)
REMOVE FUEL PUMP ASSY Disconnect the fuel pump assy connector. Remove the 2 nuts and the fuel pump assy. Remove the fuel pump insulator.
A79574
9. (a)
(b)
(c)
A79834
(d)
INSTALL FUEL PUMP ASSY Turn the crankshaft and set the camshaft to the position where the oil port of the camshaft can be seen from the fuel pump mounting hole. From the fuel pump mounting hole of the cylinder head, pour 35 to 45cc (2.14 to 2.75 cu in) engine oil into the cylinder head. For more smooth rotation, apply engine oil on the cam lobe which can be seen from the fuel pump mounting hole using fingers. Set a new fuel pump insulator and fuel pump assy with the 2 nuts. Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
1154
10. (a)
Fuel Injector Backup Ring No. 1 Fuel Injector Backup Ring No. 2 Oring Fuel injector Backup Ring No. 3
A79575
INSTALL FUEL PIPE SUBASSY NO.1 Attach a new Oring, fuel injector backup ring No. 1, No. 2 and No. 3 to the fuel pipe subassy No.1. (b) Apply a small amount of fuel on the Oring and install the fuel pipe subassy No. 1 to the fuel pump assy and the fuel delivery pipe subassy. NOTICE: Be careful not to damage both the sealing surfaces of the fuel delivery pipe and the fuel pump when installing the fuel pipe No.1. (c) Tighten the nut by hand to attach the fuel pipe subassy No. 1 to the fuel pump assy. (d) In order to secure the fuel pipe subassy No. 1 to the fuel delivery pipe subassy, tighten the 2 bolts to the specified torque. Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf) (e) Clamp the union bolt on the fuel pump assy with a 21 mm wrench and tighten the nut with the specified torque to secure the fuel pipe subassy No. 1 to the fuel pump assy using a 19 mm unionnut wrench. Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)
11. (a)
INSTALL FUEL PRESSURE PULSATION DAMPER ASSY Install the fuel pulsation damper assy to the fuel pump assy after fitting new 2 gaskets and fuel tube subassy between those assys.
A79576
(b)
SST
(c)
Using SST, install the fuel pressure pulsation damper assy to the fuel pump assy. SST 0961724011 Torque: 33 NVm (331 kgfVcm, 24 ftVlbf) Connect the fuel tube subassy.
A79570
1155
12. (a) 13. 14. 15. 16.
INSTALL ENGINE COVER BRACKET Install the engine cover bracket with the bolt. Torque: 38 NVm (388 kgfVcm, 28 ftVlbf) INSTALL AIR CLEANER CAP SUBASSY (See page 1044) CHECK FOR FUEL LEAKS INSTALL ENGINE COVER SUBASSY NO.1 Torque: 7.0 NVm (71 kgfVcm, 62 in.Vlbf) INSTALL RADIATOR SUPPORT OPENING COVER
1184
FUEL FUEL PUMP ASSY (GASOLINE)
FUEL PUMP ASSY (GASOLINE)

110U301
COMPONENTS
Seat Fixed Type: Rear Seat Cushion Assembly
x4 Rear Floor Service Hole Cover 1AZFSE: Fuel Tank Return Tube Fuel Tank Main Tube Subassy Fuel Evaporation Tube Subassy No. 2 Tube Joint Clip
Fuel Pump Connector
z Fuel Pump Gauge Retainer
Fuel Suction w/ Pump & Gage Tube Assy
z Fuel Suction Tube Set Gasket

A78441
1185
110U401
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE HINT: S 1ZZFE/3ZZFE: 111 S 1AZFE: 1115 S 1AZFSE: 1130 2. REMOVE REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 7232)
(a)
3. (a) (b)
REMOVE REAR FLOOR SERVICE HOLE COVER Remove the 4 screws, and then remove the rear floor service hole cover. Disconnect the fuel pump connector.
A78442
Tube Joint Clip 1 2
4.
A78443
Fuel Tube Joint
Nylon Tube
Oring
Tube Joint Clip Fuel Suction Plate

A60575
DISCONNECT FUEL TANK RETURN TUBE (1AZFSE ENGINE TYPE) (a) Remove the tube joint clip, and pull out the fuel return tube. NOTICE: S Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary. S Be careful of mud because the fuel tube joint has an Oring which seals the pipe and connector that can be contaminated. S Do not use any tool in this operation. S Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag. S When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
1186
5. (a)
1 Pinch
2 1 Pinch
A78444
Nylon Tube
Tube Connector
DISCONNECT FUEL TANK MAIN TUBE SUBASSY Pinch the tube connector and pull out the fuel tank main tube. NOTICE: S Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary. S Be careful of mud because the quick connector has an Oring which seals the pipe and connector that can be contaminated. S Do not use any tool in this operation. S Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag. S When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
Oring
Pipe
A75650
6.
Pinch
1 Pinch
A78445
Fuel Tube Connector Clip Nylon Tube Oring
Pipe Fuel Tube Connector

A65059
DISCONNECT FUEL EVAPORATION TUBE SUBASSY NO.2 (a) Pinch the fuel tube connector clip and pull out the fuel evaporation tube. NOTICE: S Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary. S Be careful of mud because the quick connector has an Oring which seals the pipe and connector that can be contaminated. S Do not use any tool in this operation. S Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag. S When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
SST
7.
Rib
A78446
REMOVE FUEL SUCTION W/PUMP & GAGE TUBE ASSY (a) Using SST, loosen the fuel pump gauge retainer. SST 0980814010 NOTICE: Do not use other tools in this operation. Damage to the fuel pump gauge retainer and the fuel tank may result. HINT: A rib on the fuel pump gauge retainer can be fitted into a tip of the SST.
1187
(b)
Remove the fuel pump gauge retainer.
(c) Remove the fuel suction w/ pump & gage tube. NOTICE: Be careful that the arm of the fuel sender gage should not be bent. (d) Remove the gasket from the tank.
A78447
8.
Triangle Mark Matchmark

A78448
INSTALL FUEL SUCTION W/PUMP & GAGE TUBE ASSY (a) Install a new gasket to the fuel tank. (b) Install the fuel suction w/ pump & gage tube. NOTICE: Be careful that the arm of the fuel sender gage should not be bent. (c) Align the triangle mark of the fuel suction w/ pump & gage tube with the matchmark location the fuel tank. (d) (e) Temporarily install the fuel pump gauge retainer. Using SST, tighten the fuel pump gauge retainer until the arrow mark is aligned with the center mark on the fuel tank. SST 0980814010 NOTICE: Do not use other tools in this operation. Damage to the fuel pump gauge retainer and the fuel tank may result. HINT: A rib on the fuel pump gauge retainer can be fitted into a tip of the SST.
SST
Rib
A78446
Arrow Mark
(f)
Check that the arrow mark and center mark are aligned as shown in the illustration.
A78449
1188
9.
Push
A81614
CONNECT FUEL EVAPORATION TUBE SUBASSY NO.2 (a) Push in the fuel tube connector to the pipe until it makes click sound. NOTICE: S Check if there is any damage or foreign objects on the connected part. S After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them. 10. (a) CONNECT FUEL TANK MAIN TUBE SUBASSY Push in the fuel tube connector to the pipe until it makes click sound. NOTICE: S Check if there is any damage or foreign objects on the connected part. S After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them.
Push
A81615
Tube Joint Clip 1
11.
Collar
A81616
CONNECT FUEL TANK RETURN TUBE (1AZFSE ENGINE TYPE) (a) Install in the fuel return tube with the tube joint clip. NOTICE: S Check that there is no scratch or foreign objects on the connecting part. S Check that the fuel tube joint is inserted securely. S Check that the tube joint clip is on the collar of the fuel tube joint. S After installing the tube joint clip, check that the fuel tube joint has not been pulled off.
12. CHECK FOR FUEL LEAKS HINT: S 1ZZFE/3ZZFE: 115 S 1AZFE: 1119 S 1AZFSE: 1133 13. INSTALL REAR FLOOR SERVICE HOLE COVER 14. INSTALL REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 7232)
1122
FUEL FUEL SYSTEM (1AZFE)
110UY01
INSPECTION
1. (a) INSPECT FUEL INJECTOR ASSY Inspect injector resistance (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: 13.4 to 14.2 W at 20_C (68_F) If the resistance is not as specified, replace the injector. (b) Inspect injector inspection CAUTION: This test involves highpressure fuel and electricity. Take every precaution regarding safe handling of both the fuel and the electricity. Preform this test in a safe area, and avoid any sparks or flame. Do not smoke.
(1)
Fuel Tube Connector
Obtain new No. 1 fuel pipe (part No. 239010H040) and remove the fuel tube connector from the pipe.
A50710
Fuel Tube Connector
SST (Hose)
Install the fuel tube connector to SST (hose), then connect the tube connector and the fuel pipe. SST 0926841047 (9533608070) CAUTION: Connect the fuel tube connector (quick type) after observing the precautions to prevent fuel from spraying.
(2)
B12947
SST (Hose)
SST (Union) ORing SST (Clamp)
Vinyl Tube
A51875
Install the Oring to the injector. Connect SST (union and hose) to the injector, and hold the injector and the union with SST (clamp) SST 0926841047 (0926841110, 0926841300, 9533608070) (5) Put the injector into a graduated cylinder. CAUTION: Install a suitable vinyl tube onto the injector to contain gasoline spray. (6) Operate the fuel pump.(See Page 1119)
(3) (4)
1123
(7)
Connect SST (wire) to the injector and the battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 0984230080 Injection volume:
SST
Injection volume 60 to 73 cm3 (3.6 to 4.5 cu in.) in 15 seconds Difference between each injector 13 cm3 (0.9 cu in.) or less
A50700
NOTICE: Always do the switching at the battery side. If the injection volume is not as specified, replace the injector.
(c)
Inspect leakage (1) In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. Fuel drop: 1 drop or less in 12 minutes
B00069
A16628
A32859
INSPECT FUEL PUMP Insect fuel pump resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: 0.2 to 3.0 W at 20_C (68_F) (b) Inspect fuel pump operation (1) Apply battery voltage to both the terminals. Check that the pump operates. NOTICE: S These tests must be done quickly (within 10 seconds) to prevent damage to the pump. S Keep fuel pump as far away from the battery as possible. S Always do the switching at the battery side.
2. (a)
1119
110UX01
ONVEHICLE INSPECTION
Fuel Tube Connector
1. (a)
(b) (c) (d) HINT: Part No. 239010H040

A50710
CHECK FUEL PRESSURE Discharge the pressure in the fuel system and take precautions for possible fuel spillage.(See page 1115) Check that the battery voltage is above 12 V. Disconnect the negative () battery cable. Pull out the connecter from a new fuel tube.
(e)
Remove the fuel pipe clamp No.1 from the fuel tube connector.
Fuel Pipe Clamp No.1
A60083
(f)
A
A
B12941
Disconnect the fuel tube connector from the fuel pipe while pinching part A with fingers as shown in the illustration. CAUTION: S Do not disconnect the fuel tube connector (quick type) until after you have discharged the fuel system pressure and taken appropriate steps to prevent fuel spillage. S There may be remained pressure in the fuel lines after discharging the pressure. Take precautions to prevent fuel from spraying on you or your clothing or inside the engine compartment.
1120
SST (Clip) SST SST (T joint)
No.1 Fuel Pipe
SST (Hose)
Fuel Tube Connector

B12975
Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration. SST 0926841047(9533608070),0926845014 (0926841250, 0926841200, 0926841220) (h) Wipe up any gasoline. (i) Reconnect the negative () battery cable. (j) Connect the handhand tester to the DLC3. (k) Measure the fuel pressure. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses connections, the fuel pump, the fuel filter and the fuel pressure regulator. (l) Disconnect the handheld tester from the DLC3. (m) Start the engine. (n) Measure the fuel pressure at idle. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 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/cm2, 21 psi) or more If pressure is not as specified, check the fuel pump, the pressure regulator and/or the injectors. (q) After checking the fuel pressure, disconnect the negative () battery cable and carefully remove SST and the fuel tube connector to prevent gasoline from splashing. (r) Reconnect the No. 1 fuel pipe (fuel tube connector). CAUTION: After taking the precautions, connect the fuel tube connecter (quick type). 2. CHECK FUEL PUMP OPERATION AND FUEL LEAK (a) When using the handheld tester (1) Connect the handheld tester to the DLC3. (2) Turn the ignition switch ON and the handheld tester main switch ON. NOTICE: Do not start the engine. (3) Select the active test mode on the handheld tester. (4) Perform the active test. Check that the fuel pump operates and check for fuel leaks.
(g)
1121
(b)
Battery
When not using handheld tester (1) Connect the positive (+) lead form the battery to terminal 4 of the connector and connect the negative () lead to terminal 5. (2) Check that the pump operates.
4 5
A75342
1115
FUEL SYSTEM (1AZFE)

110UW01
PRECAUTION
1. (a) (b) (c) PRECAUTION Before working on fuel system, disconnect negative () battery cable. Do not smoke or work near fire when handling the fuel system. Keep gasoline away from rubber or leather parts. 2. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: S Do not disconnect any part of the fuel system until you have discharged the fuel system pressure. S Even after discharging the fuel pressure, place a shop rag over fittings as you separate them to reduce risk of fuel spray on yourself or in the engine compartment.
Fuel Pump Connector
(a) (b) (c) (d) 3. (a)

A75341
Disconnect the fuel pump connector. Start the engine. After the engine has stopped, turn the ignition switch OFF. Disconnect the negative () battery cable. Connect the fuel pump connector. FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures. (1) Discharge the pressure in the fuel system. (See step 2) (2) Disconnect the fuel pump tube. (See page 1193) (3) Drain the fuel that remained inside the fuel pump tube. (4) (5) Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt. Place a tray under the vehicle or point of disconnection to catch any fuel that may spill.
Vinyl or Plastic Bag

B00679
1116
New Oring
CORRECT
(b)
Delivery Pipe WRONG Injector

A51878
Observe the following precautions when removing and installing fuel injectors. NOTICE: Never reuse the Oring. (1) When installing a new Oring to the injector, be careful not to damage the injector. (2) Coat the new Oring with grease or gasoline before installing. Never use engine oil, gear oil or brake oil.
Delivery Pipe Oring
(c)
Install the injector to the delivery pipe and cylinder head as shown in the illustration. Before installing the injector, be sure to apply grease or gasoline on the place where the delivery pipe contacts the Oring of the injector.
Grommet
B09613
(d)
Oring Retainer Pipe
Observe these precautions when disconnecting the fuel delivery pipe.
HINT: The structure of the metallic connector is as shown in the illustration on the left.
Nylon Tube
Housing
A50709
(1) (2)
Remove the fuel pipe clamp No.2. Find the metallic connector of the fuel tube assembly, slide it towards the vehicle rear and hold it as it is.
A75343
(3)
Assemble SST to the connection of the fuel pipe as shown the illustration. SST 0926821010
SST
A60818
1117
(4)
SST
(5)
Retainer (at 4 places)
Turn SST, align the retainers inside the connector with SST chamfered parts and insert SST into the connector. Slide SST and the connector together towards the fuel tube assembly.
Insert
A50705
(e)
Observe these following precautions when disconnecting the fuel tube connector (quick type). (1) Remove the fuel pipe clamp No.1. (2) Check that there is no dirt or mud on the pipe and around the connector before disconnecting them. Clean them if necessary.
A60083
(3)
A
Disconnect the connector from the hose while pinching part A with fingers as shown in the illustration.
A
B12941
(4)
(5)
When the connector and the pipe are stuck, push and pull the connector to release and pull the connector out from the pipe carefully. Inspect that there is no dirt or mud on the sealing surface of the disconnected pipe. Clean it away if necessary.
B12944
(6)
Vinyl Bag or plastic Bag
To prevent the disconnected pipe and connector from being damaged and foreign objects from being introduced, cover them with a vinyl or plastic bag.
A82344
1118
(f)
Push
B16534
Observe these precautions when connecting the fuel tube connectors (Quick Type): (1) Check that there is no damage or foreign objects in the connected part of the pipe. (2) Match the axis of the connector with the axis of the pipe, and push into the connector until the connector makes a click sound. If the connection is tight, apply little amount of fresh engine oil on the tip of the pipe. (3) After having finished the connection, check if the pipe and the connector are securely connected by pulling on them. (4) Check for fuel leaks.
Pull
B16535
4. (a)
CHECK FOR FUEL LEAKS Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (See page 1119)
1156
FUEL FUEL SYSTEM (1CDFTV)
FUEL SYSTEM (1CDFTV)

110CX02
INSPECTION
1. (a) INJECTION OR SUPPLY PUMP ASSY Resistance inspection. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: 1.5 to 2.3 W at 20_C (68_F)
A75346
2. (a)
INJECTOR ASSY Resistance inspection. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: 0.85 to 1.05 W at 20_C (68_F) 3. (a) COMMON RAIL ASSY Resistance inspection. (Fuel pressure sensor) (1) Using an ohmmeter, measure the resistance tween terminals 5 (PR) and 4 (E2). Resistance: 16.4 kW or less (2) Using an ohmmeter, measure the resistance tween terminals 2 (PR2) and 3 (E2S). Resistance: 16.4 kW or less (3) Using an ohmmeter, measure the resistance tween terminals 6 (VC) and 5 (PR). Resistance: 3 kW or less (4) Using an ohmmeter, measure the resistance tween terminals 1 (VCS) and 2 (PR2). Resistance: 3 kW or less Resistance inspection. (Pressure discharge valve) (1) Using an ohmmeter, measure the resistance tween terminals. Resistance: 0.85 to 1.05 W at 20_C (68_F)
E2S
PR2
VCS
be-
be-
PR E2 VC Fuel pressure sensor
A79038
be-
be-
(b)
be-
Pressure discharge valve
A79039
4. (a)
Switch Body
Vacuum
A62162
FUEL HEATER ASSY Resistance inspection. (1) Apply a vacuum of 34.7 " 5.3 kPa (260 " 40 mmHg, 10.24 " 1.57 in Hg) to the vacuum switch port. (2) Using an ohmmeter, measure the resistance between terminal 2 and switch body. Resistance: 0.5 to 20 W at 20_C (68_F)
1157
FUEL FUEL SYSTEM (1CDFTV)
5. (a)
6. (a)
LEVEL WARNING SWITCH Continuity inspection. (1) Using an ohmmeter, check that there is continuity between terminals. Specified condition: There is continuity when raising a float. There is no continuity when letting a float down. FUEL TEMPERATURE SENSOR Resistance inspection. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: Approx. 20_C (68_F) 2.21 to 2.69 W Approx. 80_C (176_F) 0.287 to 0.349 W
118
FUEL FUEL SYSTEM (1ZZFE/3ZZFE)
110UV01
INSPECTION
1. (a) FUEL INJECTOR ASSY Inspect injector resistance (1) Using an ohmmeter, measure the resistance between the terminals. Resistance:
Engine 1ZZFE 3ZZFE Rersistance 13.4 to 14.2 W 13.8 to 15.2 W Condition 20 _C (68 _F) 20 _C (68 _F)
If the resistance is not as specified, replace the injector. (b) Inspect injector inspection CAUTION: This test involves highpressure fuel and electricity. Take every precaution regarding safe handling of both the fuel and the electricity. Preform this test in a safe area, and avoid any sparks or flame. Do not smoke.
(1)
Fuel Tube Connector
Obtain new No. 1 fuel pipe (part No. 239010D030) and remove the fuel tube connector from the pipe.
A50710
Fuel Tube Connector
SST (Hose)
Install the fuel tube connector to SST (hose), then connect the tube connector and the fuel pipe. SST 0926841047 (9533608070) CAUTION: Connect the fuel tube connector (quick type) after observing the precautions to prevent fuel from spraying.
(2)
B12947
SST (Hose)
SST (Union) ORing SST (Clamp)
Vinyl Tube
A51875
Install the Oring to the injector. Connect SSTs (union and hose) to the injector, and hold the injector and the union with SST (clamp) SST 0926841047 (9533608070, 0926841110, 0926841300) (5) Put the injector into a graduated cylinder. CAUTION: Install a suitable vinyl tube onto the injector to contain gasoline spray. (6) Operate the fuel pump.(See Page 115)
(3) (4)
119
(7)
Connect SST (wire) to the injector and the battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 0984230080 Injection volume:
SST
Engine
A50700
Injection volume 60 to 73 cm3 (3.7 to 4.5 cu in.) in 15 seconds 45 to 55 cm3 (2.7 to 3.3 cu in.) in 15 seconds
Difference between each injector 13 cm3 (0.8 cu in.) or less
1ZZFE
3ZZFE
10 cm3 (0.6 cu in.) or less
NOTICE: Always do the switching at the battery side. If the injection volume is not as specified, replace the injector.
(c)
Inspect leakage (1) In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. Fuel drop:
1ZZFE 3ZZFE 1 drop or less in 12 minutes 1 drop or less in 5 minutes
B00069
A16628
A32859
INSPECT FUEL PUMP Insect fuel pump resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: 0.2 to 3.0 W at 20_C (68_F) (b) Inspect fuel pump operation (1) Apply battery voltage to both the terminals. Check that the pump operates. NOTICE: S These tests must be done quickly (within 10 seconds) to prevent damage to the pump. S Keep fuel pump as far away from the battery as possible. S Always do the switching at the battery side.
2. (a)
115
110UU01
Fuel Tube Connector
1. (a)
(b) (c) (d) HINT: Part No. 239010D030

A50710
CHECK FUEL PRESSURE Discharge the pressure in the fuel system and take precautions for possible fuel spillage. (See page 111) Check that the battery voltage is above 12 V. Disconnect the negative () battery cable. Pull out the connecter from a new fuel tube.
(e)
Disconnect the fuel tube clamp from the fuel tube connector.
A60083
(f)
A
A
B12941
116
No.1 Fuel Pipe
SST (Hose)
Fuel Tube Connector

B12975
Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration. SST 0926841047(9533608070),0926845014 (0926841250, 0926841200, 0926841220) (h) Wipe up any gasoline. (i) Reconnect the negative () battery cable. (j) Connect the handhand tester to the DLC3. (k) Measure the fuel pressure. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses connections, the fuel pump, the fuel filter and the fuel pressure regulator. (l) Disconnect the handheld tester from the DLC3. (m) Start the engine. (n) Measure the fuel pressure at idle. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 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/cm2, 21 psi) or more If pressure is not as specified, check the fuel pump, the pressure regulator and/or the injectors. (q) After checking the fuel pressure, disconnect the negative () battery cable and carefully remove SST and the fuel tube connector to prevent gasoline from splashing. (r) Reconnect the No. 1 fuel pipe (fuel tube connector). CAUTION: After taking the precautions, connect the fuel tube connecter (quick type). 2. CHECK FUEL PUMP OPERATION AND FUEL LEAK (a) When using the handheld tester (1) Connect the handheld tester to the DLC3. (2) Turn the ignition switch ON and the handheld tester main switch ON. NOTICE: Do not start the engine. (3) Select the active test mode on the handheld tester. (4) Perform the active test. Check that the fuel pump operates and check for fuel leaks.
(g)
117
(b)
Battery
When not using the handheld tester (1) Connect the positive (+) lead form the battery to terminal 4 of the connector and connect the negative () lead to terminal 5. (2) Check that the pump operates.
4 5
A75342
111
FUEL SYSTEM (1ZZFE/3ZZFE)

110UT01
PRECAUTION
Fuel Pump Connector
(a) (b) (c) (d) 3. (a)

A75341
Disconnect the fuel pump connector. Start the engine. After the engine has stopped, turn the ignition switch OFF. Disconnect the negative () battery cable. Connect the fuel pump connector. FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures. (1) Discharge the pressure in the fuel system. (See step 2) (2) Disconnect the fuel pump tube. (See page 1193) (3) Drain the fuel that remained inside the fuel pump tube.
(4) (5)
Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt. Place a tray under the vehicle or point of disconnection to catch any fuel that may spill.

B00679
112
Oring
CORRECT
(b)
Injector
Delivery Pipe WRONG
Observe the following precautions when removing and installing fuel injectors. NOTICE: Never reuse the Oring. (1) When installing a new Oring on the injector, be careful not to damage the injector. (2) Coat the new Oring with grease or gasoline before installing. Never use engine oil, gear oil or brake oil.
B10707
1ZZFE
(c)
Delivery Pipe
Install the injector to the delivery pipe and cylinder head as shown in the illustration. Before installing the injector, be sure to apply grease or gasoline on the place where the delivery pipe contacts the Oring of the injector.
Oring
Insulator 3ZZFE Delivery Pipe
Oring Grommet
Insulator
A75345
(d)
Oring Retainer Pipe
Observe these precautions when disconnecting the fuel delivery pipe.
HINT: The structure of the metallic connector is as shown in the illustration on the left.
Nylon Tube
Housing
A50709
(1) (2)
Remove the fuel pipe clamp No.2. Find the metallic connector of the fuel tube assembly, slide it towards the vehicle rear and hold it as it is.

A75344
113
(3)
Assemble SST to the connection of fuel pipe as shown in the illustration. SST 0926821010
SST
A60818
(4)
SST
(5)
Retainer (at 4 places)
Turn SST, align the retainers inside the connector with SST chamfered parts and insert SST into the connector. Slide SST and the connector together towards the fuel tube assembly.
Insert
A50705
(e)
A60083
(3)
A
A
B12941
(4)
(5)
B12944
114
(6)
A82344
(f)
Push
B16534
Pull
B16535
4. (a)
1136
FUEL FUEL SYSTEM (1AZFSE)
110V101
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 highpressure type and do not allow to inspect fuel injection volume. (a) Inspect injector resistance (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: 2.55 to 2.85 W at 20_C (68_F) If the resistance is not as specified, replace the injector. INSPECT FUEL PUMP Insect fuel pump resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: 0.2 to 3.0 W at 20_C (68_F) (b) Inspect fuel pump operation (1) Apply battery voltage to both the terminals. Check that the pump operates. NOTICE: S These tests must be done quickly (within 10 seconds) to prevent damage to the pump. S Keep fuel pump as far away from the battery as possible. S Always do the switching at the battery side. 3. INSPECT FUEL PUMP (HIGH PRESSURE) (a) Remove the engine cover. (b) Disconnect the fuel pump connector. 2. (a)
A16628
A32859
Ohmmeter
(c)
Using an ohmmeter, measure the resistance between the terminals. Resistance: 1.19 to 1.39 W at 20_C (68_F) If the resistance is not as specified, replace the fuel pump. (d) Reconnect the connector. (e) Reinstall the engine cover.
B10599
1133
110V001
Fuel Tube Connector
1. (a)
(b) (c) (d) HINT: Part No. 2390128160

A50710
CHECK FUEL PRESSURE Discharge the pressure in the fuel system and take precautions for possible fuel spillage. (See page 1130) Check that the battery voltage is above 12 V. Disconnect the negative () battery cable. Pull out the connecter from a new fuel tube.
(e)
Disconnect the fuel tube clamp from the fuel tube connector.
A60083
(f)
A
A
B12941
1134
No.1 Fuel Pipe
SST (Hose)
Fuel Tube Connector

B12975
Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration. SST 0926841047(9533608070),0926845014 (0926841250, 0926841200, 0926841220) (h) Wipe up any gasoline. (i) Reconnect the negative () battery cable. (j) Connect the handhand tester to the DLC3. (k) Measure the fuel pressure. Fuel pressure: 196 to 588 kPa (2 to 6 kgf/cm2, 28 to 85 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses connections, the fuel pump, the fuel filter and the fuel pressure regulator. (l) Disconnect the handheld 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/cm2, 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/cm2, 21 psi) or more If pressure is not as specified, check the fuel pump, the pressure regulator and/or the injectors. (q) After checking the fuel pressure, disconnect the negative () battery cable and carefully remove SST and the fuel tube connector to prevent gasoline from splashing. (r) Reconnect the No. 1 fuel pipe (fuel tube connector). CAUTION: After taking the precautions, connect the fuel tube connecter (quick type). 2. CHECK FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS (a) When using the handheld tester (1) Connect the handheld tester to the DLC3. (2) Turn the ignition switch ON and the handheld tester main switch ON. NOTICE: Do not start the engine. (3) Select the active test mode on the handheld tester. (4) Perform the active test. Check that the fuel pump operates and check for fuel leaks.
(g)
1135
(b)
Battery
4 5
A75340
3. (a) (b)
When not using the handheld tester (1) Connect the positive (+) lead form the battery to terminal 4 of the connector and connect the negative () lead to terminal 5. (2) Check that the pump operates. CHECK FUEL PUMP OPERATION (HIGH PRESSURE) Remove the No. 1 engine cover. Start the engine.
(c)
Using a sound scope, hear the operating sound of the pump. If there is no sound, replace the pump. (d) Stop the engine. (e) Reinstall the engine cover.
A13269
B12608
Handheld Tester
4. (a) (b) (c) (d)
A76859
CHECK FUEL HIGH PRESSURE Connect the handheld tester to the DLC3. Start the engine. Select the active test mode on the handheld tester. 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/cm2, 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 leakage. (e) Stop the engine. (f) Disconnect the handheld tester.
1130
FUEL SYSTEM (1AZFSE)

110UZ01
PRECAUTION
Fuel Pump Connector
(a) (b) (c) (d) 3. (a)

A75339
Disconnect the fuel pump connector. Start the engine. After the engine has stopped, turn the ignition switch OFF. Disconnect the negative () battery cable. Connect the fuel pump connector. FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures. (1) Discharge the pressure in the fuel system. (See step 2) (2) Disconnect the fuel pump tube. (See page 1193) (3) Drain the fuel that remained inside the fuel pump tube. (4) (5) Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt. Place a tray under the vehicle or point of disconnection to catch any fuel that may spill.

B00679
1131
(b)
Observe the following precautions when removing and installing fuel injectors. NOTICE: Never reuse the Oring. (1) When installing a new Oring to the injector, be careful not to damage the injector. (2) Coat the new Oring with grease or gasoline before installing. Never use engine oil, gear oil or brake oil.
(c)
A60083
(3)
A
A
B12941
(4)
(5)
B12944
(6)
A82344
1132
(d)
Push
B16534
Pull
B16535
4. (a)
11101
FUEL FUEL TANK ASSY (DIESEL)
FUEL TANK ASSY (DIESEL)

110UE01
COMPONENTS
Rear Seat Cushion Assy
Rear Floor Service Hole Cover
Fuel Pump Gauge Retainer
Fuel and Evaporation Vent Tube Subassy
Exhaust Pipe Assy Front

43 (440, 32)
Compression Spring
z Gasket
Compression Spring
z Gasket Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part Floor Panel Brace Front
30 (302, 22)
A78267
43 (440, 32)
11102
Fuel Tank to Filler Pipe Hose Breather Tube Fuel Hose
Fuel Tank Band
Fuel Tank Protector No. 1 Fuel Tank Band
40 (400, 29)
5.4 (55, 48 in.Vlbf)
Parking Brake Cable Assy No. 2

5.4 (55, 48 in.Vlbf)
5.4 (55, 48 in.Vlbf)

A78268
11103
Fuel Evaporation Tube Subassy No. 2 Fuel Tank Return Tube
Fuel Tank Main Tube Subassy
Fuel Tank Assy
A78269
11104
110UF01
Removal & Installation and Disassembly & Reassembly

1. 2. (a) (b) REMOVE REAR SEAT CUSHION ASSY (See page 7227) REMOVE REAR FLOOR SERVICE HOLE COVER Remove the 4 screws and the rear floor service hole cover. Disconnect the connector.
A63024
Quick Connector
Nylon Tube
Oring Tube Joint Clip Fuel Suction Plate

A60575
DISCONNECT FUEL TANK RETURN TUBE Remove the tube joint clip and pull out the fuel tank return tube. NOTICE: S Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary. S Be careful of mud because the quick connector has an Oring which seals the pipe and the connector that can be contaminated. S Do not use any tool in this operation. S Do not bend or twist the nylon tube. S Keep the plug free of foreign objects. S To protect the tube, cover it with a vinyl or a plastic bag after checking.
3. (a)
4. (a)
A63025
DISCONNECT FUEL TANK MAIN TUBE SUBASSY Pinch the tube connector then pull out the fuel tank main tube. NOTICE: S Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary. S Be careful of mud because the quick connector has an Oring which seals the pipe and the connector that can be contaminated. S Do not use any tool in this operation. S Do not bend or twist the nylon tube. S To protect the tube, cover it with a vinyl or a plastic bag after checking. S When the connector and the pipe are stuck, push and pull the connector to release. Pull out the connector from the pipe carefully.
11105
5.
A63026
Nylon Tube Fuel Tube Connector Clip
Oring
Pipe
A60576
DISCONNECT FUEL EVAPORATION TUBE SUBASSY NO.2 (a) Pinch the quick connector then pull out the fuel evaporation tube subassy No. 2. NOTICE: S Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary. S Be careful of mud because the quick connector has an Oring which seals the pipe and the connector that can be contaminated. S Do not use any tool in this operation. S Do not bend or twist the nylon tube. S To protect the tube, cover it with a vinyl or a plastic bag after checking. S When the connector and the pipe are stuck, push and pull the connector to release. Pull out the connector from the pipe carefully.
6.
SST
A62989
REMOVE FUEL AND EVAPORATION VENT TUBE SUBASSY (a) Using SST, loosen the retainer. SST 0980814010 (b) Remove the retainer. (c) Pull out the fuel pump assembly. CAUTION: Be careful that the arm of the sender gauge should not bent.
7. 8. 9.
DRAIN FUEL REMOVE FLOOR PANEL BRACE FRONT (See page 1510) REMOVE EXHAUST PIPE ASSY FRONT (See page 1510)
10. (a)
REMOVE FUEL TANK PROTECTOR NO.1 Remove the 4 bolts and the fuel tank protector.
A77883
11106
11. (a)
REMOVE PARKING BRAKE CABLE ASSY NO.2 Remove the 2 set bolts of the parking brake cable.
A77884
12. (a)
A77885
13. (a)
DISCONNECT BREATHER TUBE FUEL HOSE Loosen the hose clamp and disconnect the fuel tank breather hose.
A77886
14. (a)
DISCONNECT FUEL TANK TO FILLER PIPE HOSE Loosen the hose clamp and disconnect the fuel tank to filler pipe hose.
A77887
15.
DISCONNECT FUEL TANK RETURN TUBE
A78450
11107
16. (a)
3 1
A81588
Fuel Tube Connector Retainer
DISCONNECT FUEL TANK MAIN TUBE SUBASSY Pinch the tab of the retainer to remove the lock claws and pull down it as shown in the illustration. (b) Pull out the fuel tank main tube. NOTICE: S Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary. S Be careful of mud because the quick connector has an Oring which seals the pipe and the connector that can be contaminated. S Do not use any tool in this operation. S Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or a plastic bag. S When the pipe and connector are stuck, push and pull the connector to release. Pull out the connector from the pipe carefully.
Oring
Pipe
A63387
17. (a) (b)
REMOVE FUEL TANK ASSY Set up a transmission jack under the fuel tank. Remove the 4 bolts and 2 fuel tank bands, and then remove the fuel tank.
A77890
18. (a)
REMOVE FUEL TANK MAIN TUBE SUBASSY Unfasten the 5 claws, and remove the fuel tank return tube from the fuel tank.
A77894
19. (a)
REMOVE FUEL EVAPORATION TUBE SUBASSY NO.2 Unfasten the claw, and remove the fuel evaporation tube from the fuel tank.
A78270
11108
20. (a) 21.
REMOVE FUEL TANK MAIN TUBE SUBASSY Unfasten the 4 claws, and remove the fuel tank main tube from the fuel tank. INSTALL FUEL TANK MAIN TUBE SUBASSY
A77892
Upper Fuel Tank Rear
22. (a)
INSTALL FUEL EVAPORATION TUBE SUBASSY NO.2 Install the hose clamp as shown in the illustration.
Hose Clamp
A77893
23. 24.
INSTALL FUEL TANK RETURN TUBE INSTALL FUEL TANK ASSY Torque: 40 NVm (400 kgfVcm, 29 ftVlbf)
25. (a)
CONNECT FUEL TANK MAIN TUBE SUBASSY Push in the fuel tube connector to the pipe, and push up retainer to lock the claws.
A81618
NOTICE: S Check if there is any damage or foreign objects on the connected part. S After connecting, check if the quick connector and the pipe are securely connected by pulling on them. 26. CONNECT FUEL TANK RETURN TUBE 27. CONNECT FUEL TANK TO FILLER PIPE HOSE 28. CONNECT BREATHER TUBE FUEL HOSE 29. INSTALL PARKING BRAKE CABLE ASSY NO.3 Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf) 30. INSTALL PARKING BRAKE CABLE ASSY NO.2 Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf) 31. INSTALL FUEL TANK PROTECTOR NO.1 Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf) 32. INSTALL EXHAUST PIPE ASSY FRONT (See page 1510) 33. ADD FUEL
11109
34. (a) (b)

Mark
INSTALL FUEL AND EVAPORATION VENT TUBE SUBASSY Align the arrow marks of the fuel pump bracket and the fuel tank. Temporarily install the retainer.
A63379
(c)
SST
Mount SST to the retainer. SST 0980814010
A62989
(d)
Area
(e)
Tighten the retainer until the arrow mark located on the retainer is positioned within the area shown in the illustration. Check that the arrow marks of the fuel pump bracket and fuel tank are aligned.
Arrow Mark
A63380
35.
A64697
CONNECT FUEL EVAPORATION TUBE SUBASSY NO.2 (a) Push in the quick connector to the pipe until connector makes click sound. NOTICE: S Check if there is any damage or foreign objects on the connected part of the pipe. S After connecting, check if the pipe and the connector are securely connected by pulling on them. 36. (a) CONNECT FUEL TANK MAIN TUBE SUBASSY Push in the quick connector to the pipe until connector makes click sound. NOTICE: S Check if there is any damage or foreign objects on the connected part of the pipe. S After connecting, check if the pipe and the connector are securely connected by pulling on them.
A64698
11110
38. 39. 40. 41. 42.
37. CONNECT FUEL TANK RETURN TUBE (a) Connect the fuel tank return tube with the tube joint clip. NOTICE: S Check that there is no scratch or foreign objects on the connecting parts. S Check that the connector is inserted securely. S Check that the clip of the tube joint is on the collar of the connector. S After installing the tube joint clip, check that the conA64699 nector is not pulled off. CHECK FOR FUEL LEAKS (See page 1160) CHECK FOR EXHAUST GAS LEAKS INSTALL FLOOR PANEL BRACE FRONT (See page 1510) INSTALL REAR FLOOR SERVICE HOLE COVER INSTALL REAR SEAT CUSHION ASSY (See page 7227)
1189
FUEL FUEL TANK ASSY (GASOLINE)
FUEL TANK ASSY (GASOLINE)

110U601
COMPONENTS
Seat Fixed Type: Rear Seat Cushion Assembly
x4 Rear Floor Service Hole Cover 1AZFSE: Fuel Tank Return Tube Fuel Tank Main Tube Subassy Fuel Evaporation Tube Subassy No. 2 Tube Joint Clip
Fuel Pump Connector
z Fuel Pump Gauge Retainer
Fuel Suction w/ Pump & Gage Tube Assy

A78441
1190
1ZZFE/3ZZFE: w/o HID Sensor: Clip
RHD: Front Floor Footrest
z Exhaust Pipe Gasket
Floor Carpet Assy Front z Exhaust Pipe Gasket Exhaust Pipe Assy Front
43 (440, 32)
Compression Spring
Floor Panel Brace Front z Exhaust Pipe Gasket
30 (302, 22) 43 (440, 33)
Compression Spring 1AZFE: Exhaust Pipe Assy Center z Exhaust Pipe Gasket
43 (440, 32)
Compression Spring
Floor Panel Brace Front z Exhaust Pipe Gasket

43 (440, 32) 30 (302, 22)
1AZFE (Leaded Gasoline) 1AZFSE: Exhaust Pipe Assy Center z Exhaust Pipe Gasket
43 (440, 32)
Compression Spring
Floor Panel Brace Front
43 (440, 32)
30 (302, 22)

A78517
1191
Fuel Tank to Filler Pipe Hose Fuel Hose No. 1
Fuel Tank Assy
Fuel Tank Band Subassy No. 1
40 (400, 29)
40 (400, 29)
Fuel Tank Band Subassy No. 1 LH
Fuel Tank Protector No. 1 x4

5.4 (54, 47 in.Vlbf)
5.0 (51, 44 in.Vlbf)
5.0 (51, 44 in.Vlbf)

A77881
1192
1AZFSE: Fuel Tank Return Tube
Fuel Evaporation Tube Subassy No. 2
Fuel Tank Main Tube Subassy
Fuel Tank Assy
A77882
1193
110U501
Removal & Installation and Disassembly & Reassembly

1. DISCHARGE FUEL SYSTEM PRESSURE HINT: S 1ZZFE/3ZZFE: 111 S 1AZFE: 1115 S 1AZFSE: 1130 2. REMOVE REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 7232) 3. REMOVE COVER, RR FLOOR SERVICE HOLE (See page 1185) 4. DISCONNECT FUEL TANK RETURN TUBE (1AZFSE ENGINE TYPE) (See page 1185) 5. DISCONNECT FUEL TANK MAIN TUBE SUBASSY (See page 1185) 6. DISCONNECT FUEL EVAPORATION TUBE SUBASSY NO.2 (See page 1185) 7. REMOVE FUEL SUCTION W/PUMP & GAGE TUBE ASSY (See page 1185) SST 0980814010 8. DRAIN FUEL 9. REMOVE FRONT FLOOR FOOTREST (W/O HID SENSOR) 10. REMOVE FLOOR PANEL BRACE FRONT (See page 152)
11. (a) (b)
REMOVE EXHAUST PIPE ASSY CENTER (1ZZFE/3ZZFE ENGINE TYPE) Using a clip remover, remove the 2 clips. (w/o HID Sensor) Open the floor carpet. (w/o HID Sensor)
A78493
w/o HID Sensor:
(c) (d)
Disconnect the heated oxygen sensor connector. Remove the grommet. (w/o HID Sensor)
(c)
(d)
w/ HID Sensor:
(c)
A80060
1194
(e) (f) (g)
Remove the 4 bolts and 4 compression springs. Remove the exhaust pipe front from the 2 exhaust pipe supports. Remove each gasket from the exhaust manifold and the exhaust pipe front.
(e)
(e) (f)
(f)
(e)
(e)
A78518
1195
12. (a) (b) (c)
REMOVE EXHAUST PIPE ASSY CENTER (1AZFE/1AZFSE ENGINE TYPE) Remove the 4 bolts and 2 compression springs. Remove the exhaust pipe center and the gasket from the 2 exhaust pipe supports. Remove the gasket from the exhaust pipe center.
(a) (b) (a)
(b)
(a)
(a)
A78519
13. (a)
REMOVE FUEL TANK PROTECTOR NO.1 Remove the 4 bolts, and then remove the fuel tank protector.
A77883
14. (a)
A77884
1196
15. (a)
A77885
16. (a)
DISCONNECT BREATHER TUBE FUEL HOSE Loosen the hose clamp and disconnect the fuel tank breather hose.
A77886
17. (a)
DISCONNECT FUEL TANK TO FILLER PIPE HOSE Loosen the hose clamp and disconnect the fuel tank to filler pipe hose.
A77887
18.
DISCONNECT FUEL TANK RETURN TUBE (1AZFSE ENGINE TYPE)
A78450
1197
2 Pinch
19. (a)
3 1
2 Pinch Retainer
A77888
Fuel Tube Connector
Retainer
Oring
Pipe
A63387
DISCONNECT FUEL TANK MAIN TUBE SUBASSY Pinch the tab of the retainer to remove the lock claws and pull down it as shown in the illustration. (b) Pull out the fuel tank main tube. NOTICE: S Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary. S Be careful of mud because the quick connector has an Oring which seals the pipe and the connector that can be contaminated. S Do not use any tool in this operation. S Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag. S When the pipe and connector are stuck, push and pull the connector to release. Pull out the connector from the pipe.
20.
Pinch 1
1 Pinch
A77889
Nylon Tube Fuel Tube Connector Clip
DISCONNECT FUEL EVAPORATION TUBE SUBASSY NO.2 (a) Pinch the fuel tube connector clip and pull out the fuel evaporation tube. NOTICE: S Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary. S Be careful of mud because the quick connector has an Oring which seals the pipe and the connector that can be contaminated. S Do not use any tool in this operation. S Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag. S When the pipe and connector are stuck, push and pull the connector to release. Pull out the connector from the pipe.
Fuel Tube Connector
Oring
Pipe
A60576
21. (a) (b)
REMOVE FUEL TANK ASSY Set a transmission jack to the fuel tank. Remove the 4 bolts and the 2 fuel tank bands, and then remove the fuel tank.
A77890
1198
22. (a)
REMOVE FUEL TANK RETURN TUBE (1AZFSE ENGINE TYPE) Unfasten the 5 claws and remove the fuel tank return tube from the fuel tank.
A77894
23. (a)
REMOVE FUEL EVAPORATION TUBE SUBASSY NO.2 Unfasten the 4 claws and remove the fuel evaporation tube from the fuel tank.
A77891
24. (a) 25.
REMOVE FUEL TANK MAIN TUBE SUBASSY Unfasten the 4 claws and remove the fuel tank main tube from the fuel tank. INSTALL FUEL TANK MAIN TUBE SUBASSY
A77892
Upper Fuel Tank Rear
26. (a) 27. 28.
INSTALL FUEL EVAPORATION TUBE SUBASSY NO.2 Install the hose clamp as shown in the illustration. INSTALL FUEL TANK RETURN TUBE (1AZFSE ENGINE TYPE) INSTALL FUEL TANK ASSY Torque: 40 NVm (400 kgfVcm, 29 ftVlbf)
Hose Clamp
A77893
29.
Push
A81617
CONNECT FUEL EVAPORATION TUBE SUBASSY NO.2 (a) Push in the fuel tube connector to the pipe until it makes click sound. NOTICE: S Check if there is any damage or foreign objects on the connected part. S After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them.
1199
30. (a)
Push 1 2 Retainer
A81618
CONNECT FUEL TANK MAIN TUBE SUBASSY Push in the fuel tube connector to the pipe until it makes click sound, and then push up the retainer to the claws lock. NOTICE: S Check if there is any damage or foreign objects on the connected part. S After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them. 31. CONNECT FUEL TANK RETURN TUBE (1AZFSE 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 NVm (51 kgfVcm, 44 in.Vlbf) 35. INSTALL PARKING BRAKE CABLE ASSY NO.2 Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf) 36. INSTALL FUEL TANK PROTECTOR NO.1 Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf) 37. INSTALL EXHAUST PIPE ASSY CENTER (1ZZFE/3ZZFE 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 supports (d) Tighten the 4 compression springs and 4 bolts. Torque: 43 NVm (440 kgfVcm, 32 ftVlbf) (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 (1AZFE/1AZFSE 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.
A77857
New Gasket
A78440
A77857
11100
New Gasket
(b) (c) (d)
Install a new gasket to the the exhaust pipe center (exhaust pipe tail side) as shown in the illustration. Install a new gasket (exhaust pipe front side) and the exhaust pipe center to the 2 exhaust pipe supports. Tighten the 2 compression springs and 4 bolts. Torque: 43 NVm (440 kgfVcm, 32 ftVlbf)
A78440
39. 40. 41. 42. 43. 44. HINT:

S S S
ADD FUEL INSTALL FUEL SUCTION W/PUMP & GAGE TUBE ASSY (See page 1185) SST 0980814010 CONNECT FUEL EVAPORATION TUBE SUBASSY NO.2 (See page 1185) CONNECT FUEL TANK MAIN TUBE SUBASSY (See page 1185) CONNECT FUEL TANK RETURN TUBE (1AZFSE ENGINE TYPE) (See page 1185) CHECK FOR FUEL LEAKS 1ZZFE/3ZZFE: 115 1AZFE: 1119 1AZFSE: 1133 CHECK FOR EXHAUST GAS LEAKS INSTALL FLOOR PANEL BRACE FRONT (See page 152) INSTALL REAR FLOOR SERVICE HOLE COVER INSTALL REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 7232) INSTALL FRONT FLOOR FOOTREST (W/O HID SENSOR)
45. 46. 47. 48. 49.
1166
FUEL INJECTION OR SUPPLY PUMP ASSY (1CDFTV)
INJECTION OR SUPPLY PUMP ASSY (1CDFTV)

110U901
COMPONENTS
Clip

8.0 (82, 71 in.Vlbf) 5.0 (51, 44 in.Vlbf)
Clip Retainer Injector Driver V (Cooler Compressor to Crankshaft Pulley) Belt No. 1
72 (734, 53) 52 (530, 38) 52 (530, 38)
Radiator Support Opening Cover Engine Cover No. 1
Engine Mounting Insulator Subassy RH

39 (398, 29)
Power Steering Idle Pulley Bracket Radiator Hose Outlet
52 (530, 38)
Air Cleaner Cap w/ Hose Air Cleaner Element
7.0 (71, 62 in.Vlbf) 6.0 (61, 53 in.Vlbf)
Air Cleaner Case
Clip
Radiator Reserve Tank Assy
Engine Under Cover RH Engine Under Cover Subassy No. 1 Clip Nm (kgfcm, ftlbf) : Specified torque
A79435
1167
* Gasket
Timing Chain Cover Plate Timing Belt No. 2 Cover Seal Washer
7.4 (76, 66 in.lbf)
Timing Belt
x7 Transverse Engine Engine Mounting Bracket

37 (375, 27)
9.0 (92, 80 in.lbf)
21 (214, 15)
Generator V belt
64 (650, 47)
Timing Belt Tensioner * Gasket
Timing Belt No.1 Cover Timing Belt Guide Seal Washer
x5
7.4 (76, 66 in.lbf)
Crankshaft Pulley
180 (1,837, 133) 40 (408, 30) 2.2 (22, 19 in.lbf)
Glow Plug Screw Grommet Glow Plug No.1 Connector Glow Plug Assy
Idler Pulley
Nm (kgfcm, ftlbf) : Specified torque * Replace only if damaged

A61211
1168
* 42 (428, 31) 46 (469, 34)
5.0 (51, 44 in.Vlbf)
Injection Pipe Clamp No. 2 Injection Pipe Subassy

* 31 (316, 23) 34 (347, 25) * 42 (428, 31) 46 (469, 34) * 31 (316, 23) 34 (347, 25)
z Fuel Inlet Pipe Subassy
5.0 (51, 44 in.Vlbf)
z Gasket
8.8 (90, 78 in.Vlbf)
Injection Pump to Fuel Pipe Fuel Hose
Water Inlet Injection Pump to Fuel Filter Fuel Hose or Pipe

21 (210, 15)
Injection Pump Drive Pulley

64 (650, 47) 18 (184, 13)
Injection or Supply Pump Assy

21 (210, 15)
Oil Level Gage Guide z Oring Oil Level Gage Subassy Nm (kgfcm, ftlbf) : Specified torque * Use SST
A79436
1169
110UA01
REPLACEMENT
1. 2. 3. 4. 5. 6. 7. 8. (a) 9. 10. (a) 11. 12. 13. (a) (b) (c) 14. 15. REMOVE FRONT WHEEL RH DRAIN ENGINE COOLANT (See page 1644) REMOVE ENGINE UNDER COVER SUBASSY NO.1 REMOVE ENGINE UNDER COVER RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE AIR CLEANER ASSY (See page 1160) REMOVE ENGINE COVER NO.1 Remove the 5 nuts and the engine cover. REMOVE RADIATOR RESERVE TANK ASSY (See page 1650) DISCONNECT RADIATOR HOSE OUTLET Disconnect the radiator hose outlet from the water inlet. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14269) REMOVE GENERATOR V BELT (See page 14269) REMOVE INJECTOR DRIVER Remove the 2 nuts which are used to secure the injector driver. Disconnect the injector driver connector and the harness clamp. Remove the injector driver. REMOVE ENGINE MOUNTING INSULATOR SUBASSY RH (See page 14307) REMOVE CRANKSHAFT PULLEY (See page 14307) SST 0921354015 (9010508076), 0933000021, 0995050013 (0995105010, 0995205010, 0995305020, 0995405031) 16. (a) REMOVE IDLER PULLEY SUBASSY Remove the bolt and washer, then remove the idler pulley.
A15950
17. 18. 19. 20. (a) 21. 22. 23.
REMOVE TIMING BELT NO.2 COVER (See page 14307) REMOVE TIMING BELT NO.1 COVER (See page 14307) REMOVE TIMING BELT GUIDE REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Remove the 6 bolts and the engine mounting bracket. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14307) REMOVE TIMING CHAIN COVER PLATE (See page 14307) REMOVE TIMING BELT (See page 14307)
1170
SST
A79148
24. REMOVE FUEL INLET PIPE SUBASSY NOTICE: After removing the fuel inlet pipe, cover the common rail and injection pump with vinyl tape to prevent dust from being introduced. (a) Remove the wire bracket and slide the engine wire. (b) Using SST, remove the fuel inlet pipe from the common rail. SST 0902312700 (c) Using SST, remove the fuel inlet pipe from the injection pump. SST 0902312700
25. (a) (b)
SST
(c)
A79143
(d)
26.
REMOVE INJECTION PIPE SUBASSY NO.1 Remove the 2 nuts, then remove the 2 upper infection pipe clamps from the intake manifold. Using SST, remove the injection pipe from the common rail side. SST 0902312700 Using SST, remove the injection pipe from the injector side. SST 0902312700 After removing the fuel pipe, to prevent dust or foreign objects from being introduced, cover the common rail with vinyl tape and protect the injector inlet with a vinyl or a plastic bag. NO.2
HINT: Perform the same procedures as injection pipe No. 1. 27. REMOVE INJECTION PIPE SUBASSY NO.3 SST 0902312700 HINT: Perform the same procedures as injection pipe No. 1. 28. REMOVE INJECTION PIPE SUBASSY NO.4 SST 0902312700 HINT: Perform the same procedures as injection pipe No. 1.
1171
29. (a)
REMOVE INTAKE MANIFOLD INSULATOR NO.1 Remove the 2 bolts and the intake manifold insulator.
A79150
30. 31. 32.
REMOVE OIL LEVEL GAGE SUBASSY REMOVE OIL LEVEL GAGE GUIDE (See page 1722) REMOVE WATER INLET (See page 1650)
33. (a)
DISCONNECT INJECTION PUMP TO FUEL PIPE FUEL HOSE Disconnect the injection pump to fuel pipe fuel hose from the supply pump.
A79151
34. (a)
DISCONNECT INJECTION PUMP TO FUEL FILTER FUEL HOSE OR PIPE Disconnect the injection pump to fuel filter fuel hose or pipe from the supply pump.
A79152
35. (a)
SST
REMOVE INJECTION PUMP DRIVE PULLEY Using SST, remove the pulley nut. SST 0996010010 (0996201000, 0996301000)
A62166
1172
(b)
Using SST, remove the injection pump drive pulley. SST 0995050013 (0995105010, 0995205010, 0995305020, 0995405021)
SST
A62779
36. (a)
REMOVE INJECTION OR SUPPLY PUMP ASSY Remove the 2 nuts and the injection pump.
A79153
37.
INSTALL INJECTION OR SUPPLY PUMP ASSY Torque: 21 NVm (210 kgfVcm, 15 ftVlbf)
38. (a)
SST
INSTALL INJECTION PUMP DRIVE PULLEY Using SST, install the pulley nut. SST 0996010010 (0996201000, 0996301000) Torque: 64 NVm (650 kgfVcm, 47 ftVlbf)
A62166
39. 40. 41.
INSTALL WATER INLET (See page 1650) INSTALL OIL LEVEL GAGE GUIDE (See page 1722) INSTALL INTAKE MANIFOLD INSULATOR NO.1 Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf) 42. INSTALL INJECTION PIPE SUBASSY NO.1 NOTICE: 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.
1173
Fulcrum Length 30 cm
(c)
SST
A79147
Using SST, tighten the nut of the injection pipe to the common rail side. SST 0902312700 Torque: 42 NVm (428 kgfVcm, 31 ftVlbf) for a used pipe using SST 46 NVm (469 kgfVcm, 34 ftVlbf) for a used pipe not using SST 31 NVm (316 kgfVcm, 23 ftVlbf) for a new pipe using SST 34 NVm (347 kgfVcm, 25 ftVlbf) for a new pipe not using SST Use a torque wrench with a fulcrum length of 30 cm (11.81 in.) Check if the used pipe has deflection or is installed properly after injection pipe is reassembled. If there is deflection or if it can not be installed properly, replace the used pipe with a new pipe. Using SST, tighten the nut of the injection pipe to the injector side. SST 0902312700 Torque: 42 NVm (428 kgfVcm, 31 ftVlbf) for a used pipe using SST 46 NVm (469 kgfVcm, 34 ftVlbf) for a used pipe not using SST 31 NVm (316 kgfVcm, 23 ftVlbf) for a new pipe using SST 34 NVm (347 kgfVcm, 25 ftVlbf) for a new pipe not using SST
HINT:
S S
(d)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.) S Check if the used pipe has deflection or is installed properly after injection pipe is reassembled. If there is deflection 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 NVm (51 kgfVcm, 44 in.Vlbf) INSTALL INJECTION PIPE SUBASSY NO.2 SST 0902312700
S
43.
HINT: Perform the same procedures as injection pipe No. 1. 44. INSTALL INJECTION PIPE SUBASSY NO.3 SST 0902312700 HINT: Perform the same procedures as injection pipe No. 1. 45. INSTALL INJECTION PIPE SUBASSY NO.4 SST 0902312700 HINT: Perform the same procedures as injection pipe No. 1.
1174
47. 48. 49. 50. 51.
46. INSTALL FUEL INLET PIPE SUBASSY NOTICE: 30 cm S In case of having the injection pump replaced, must (11.81 in.) replace the fuel inlet pipe, too. S When assembling the pipe, perform the operation with the engine cold under room temperature. SST (a) Temporarily install the fuel inlet pipe. (b) Using SST, tighten the nut of the fuel inlet pipe to the common rail side. A79149 SST 0902312700 Torque: 42 NVm (428 kgfVcm, 31 ftVlbf) for a used pipe using SST 46 NVm (469 kgfVcm, 34 ftVlbf) for a used pipe not using SST 31 NVm (316 kgfVcm, 23 ftVlbf) for a new pipe using SST 34 NVm (347 kgfVcm, 25 ftVlbf) for a new pipe not using SST HINT: S Use a torque wrench with a fulcrum length of 30 cm (11.81 in.) S Check if the used pipe has deflection or is installed properly 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 injection pump side. SST 0902312700 Torque: 42 NVm (428 kgfVcm, 31 ftVlbf) for a used pipe using SST 46 NVm (469 kgfVcm, 34 ftVlbf) for a used pipe not using SST 31 NVm (316 kgfVcm, 23 ftVlbf) for a new pipe using SST 34 NVm (347 kgfVcm, 25 ftVlbf) for a new pipe not using SST HINT: S Use a torque wrench with a fulcrum length of 30 cm (11.81 in.) S Check if the used pipe has deflection or is installed properly 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. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14307) SST 0996010010 (0996201000, 0996301000) INSTALL TIMING BELT (See page 14307) CHECK VALVE TIMING (See page 14307) INSTALL TIMING CHAIN COVER PLATE (See page 14307) INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Torque: 37 NVm (375 kgfVcm, 27 ftVlbf) for 14mm head bolt 64 NVm (650 kgfVcm, 47 ftVlbf) for 17mm head bolt
1175
52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66.
INSTALL TIMING BELT GUIDE (See page 14307) INSTALL TIMING BELT NO.1 COVER (See page 14307) INSTALL TIMING BELT NO.2 COVER (See page 14307) INSTALL IDLER PULLEY SUBASSY Torque: 40 NVm (408 kgfVcm, 30 ftVlbf) INSTALL CRANKSHAFT PULLEY (See page 14307) SST 0921354015 (9010508076), 0933000021 INSTALL ENGINE MOUNTING INSULATOR SUBASSY RH (See page 14307) INSTALL INJECTOR DRIVER Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf) ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14269) INSTALL RADIATOR RESERVE TANK ASSY (See page 1650) INSTALL ENGINE COVER NO.1 Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf) INSTALL AIR CLEANER ASSY (See page 1160) INSTALL FRONT WHEEL RH Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf) ADD ENGINE COOLANT (See page 1644) CHECK FOR ENGINE COOLANT LEAKS (See page 1637) CHECK FOR FUEL LEAKS (See page 1160)
1158
FUEL INJECTOR ASSY (1CDFTV)
INJECTOR ASSY (1CDFTV)

110U701
COMPONENTS
Radiator Support Opening Cover Clip

8.0 (82, 71 in.Vlbf)
Retainer
Engine Cover No. 1
8.3 (85, 73 in.Vlbf)
Vacuum Reservoir Subassy
Union To Connector Tube Hose
Air Cleaner Cap w/ Hose Air Cleaner Element

25 (255, 18) 7.0 (71, 62 in.Vlbf)
Air Cleaner Case
Air Tube No. 1
25 (255, 18)

A79434
1159
13 (135, 9.7)
z Nozzle Holder Seal Cylinder Head Cover Subassy
Gasket
z Gasket
18 (184, 13)
Nozzle Leakage Pipe Assy
22 (224, 16)
5.0 (51, 44 in.lbf)
z Gasket
*1 31 (316, 23) 34 (347, 25)
Injection Pipe Clamp No. 2
27 (270, 20)
Washer Nozzle Holder Clamp Injector Assy z Fuel Injector Backup Ring No. 1 z Oring z Injection Nozzle Seat Timing Belt No. 2 Cover *2 Gasket z Injection Pipe Subassy
*1 31 (316, 23) 34 (347, 25)
7.4 (75, 65 in.lbf)
Seal Washer
z Gasket
21 (214, 15)
8.8 (90, 79 in.lbf)
Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part *1 Use SST *2 Replace only if damaged
Nozzle Leakage Pipe No. 2

A79442
1160
110U801
REPLACEMENT
HINT: Each injector assembly has a characteristic fuel injecting behavior. The ECM stores compensation codes which are used to optimize fuel injection for the injectors. When replacing the injector assembly, a compensation code for the new injector assembly must be set to the ECM. 1. REMOVE VACUUM RESERVOIR SUBASSY (a) Disconnect the 2 vacuum hoses and the connector. (b) Remove the 2 bolts and the vacuum reservoir. 2. REMOVE RADIATOR SUPPORT OPENING COVER 3. REMOVE ENGINE COVER NO.1 (a) Remove the 5 nuts and the engine cover. 4. 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. 5. REMOVE AIR TUBE NO.1 (See page 14270)
6. (a) (b)
SST
(c)
A79143
(d)
7.
REMOVE INJECTION PIPE SUBASSY NO.1 Remove the 2 nuts and 2 upper infection pipe clamps from the intake manifold. Using SST, remove the injection pipe from the common rail side. SST 0902312700 Using SST, remove the injection pipe from the injector side. SST 0902312700 After removing the fuel pipe, to prevent dust or foreign objects from being introduced, cover the common rail with vinyl tape and protect the injector inlet with a vinyl or plastic bag. NO.2
HINT: Perform the same procedures as injection pipe No. 1. 8. REMOVE INJECTION PIPE SUBASSY NO.3 SST 0902312700 HINT: Perform the same procedures as injection pipe No. 1. 9. REMOVE INJECTION PIPE SUBASSY NO.4 SST 0902312700 HINT: Perform the same procedures as injection pipe No. 1. 10. REMOVE TIMING BELT NO.2 COVER (a) Remove the 7 bolts and 7 seal washers, then remove the timing belt cover.
1161
11. (a)
REMOVE NOZZLE HOLDER SEAL Using a screwdriver, pry out the 4 nozzle holder seals.
A09656
12. (a)
REMOVE CYLINDER HEAD COVER SUBASSY Remove the 10 bolts and the cylinder head cover.
A79144
13. (a)
REMOVE NOZZLE LEAKAGE PIPE ASSY Remove the union bolt and the 4 hollow screws, then remove the nozzle leakage pipe and the 5 gaskets. NOTICE: When removing then nozzle leakage pipe, place the shop rag under the pipe to protect the cylinder head from the fuel remaining inside the pipe.
A80110
14. REMOVE NOZZLE HOLDER CLAMP (a) Remove the 4 bolts, 4 washers and 4 nozzle holder clamps. 15. REMOVE INJECTOR ASSY (a) Remove the 4 injectors from the cylinder head. (b) Remove the Orings and backup rings from each injector. (c) Remove the 4 nozzle seats from the cylinder head. 16. REGISTRATION OF INJECTOR COMPENSATION CODE (See page 05528) HINT: Each injector assembly has a characteristic fuel injecting behavior. When replacing the injector assembly, store them in correct order so that they can be returned to the original locations when reassembling. 17. INSTALL INJECTOR ASSY (a) Install 4 new nozzle seats to the cylinder head.
1162
Backup ring
(b) (c)
Install new backup rings and Orings to each injector. Apply a light coat of engine oil onto the Orings on each injector. (d) Install the injector to the cylinder head. NOTICE: Fit the injectors to the nozzle seat.
Oring
A79187
(e)
B08249
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: S Pay attention to the mounting orientation of the washer. S When temporarily attaching the nozzle holder clamp and the mounting bolt, be careful not to orient them at an angle. HINT: Apply a light coat of engine oil on the threads of the nozzle holder clamp bolts. (f) Install the injection pipe No. 1, No. 2, No. 3 and No. 4, tighten the nuts by hand. (g) Install new 5 gaskets and the leakage pipe No. 1. Tighten the 4 hollow screws by hand. (h) Tighten the 4 nozzle holder clamp bolts. Torque: 26 NVm (265 kgfVcm, 19 ftVlbf) (i) Remove the 4 injection pipes. 18. INSTALL NOZZLE LEAKAGE PIPE ASSY (a) Install the nozzle leakage pipe and 5 new gaskets. NOTICE: When installing the gaskets, pay attention to the mounting orientation. Install the gasket so that the joint portion of the gasket comes within the ranges shown in the illustration. (b) Apply a light coat of oil onto the 4 hollow screws and the union bolt. (c) Tighten the 4 hollow screws and the union bolt by hand. (d) Tighten the 4 hollow screws and the union bolt. Torque: 18 NVm (184 kgfVcm, 13 ftVlbf) for hollow screw 22 NVm (224 kgfVcm, 16 ftVlbf) for union bolt (e) Check that there are no leaks from the nozzle leakage pipe connection. (1) Disconnect the fuel hose, and remove the bolt, the check valve and the nozzle leakage No. 2 pipe and the gasket.
90_
180_
A80111
1163
(2)
Install the bolt, the nozzle leakage No. 2 pipe and the gasket to the cylinder head with SST. SST 0928000010 Torque: 8.8 NVm (90 kgfVcm, 79 in.Vlbf) for bolt 21 NVm (214 kgfVcm, 15 ftVlbf) for SST (3) Apply a light coat of soapy water (any fluid to detect fuel leakage) on the nozzle leakage pipe No. 2 connection.
Union Bolt New Gasket
(4)
Hollow Screw
Using SST (turbocharger pressure gauge), attach SST to the fuel return side of the nozzle leakage No. 2 pipe, and maintain 100 kPa (1.0 kgf/cm2, 14.5 psi) of pressure for 60 seconds to check that there are no bubbles from the pipe connection. SST 0999200242 (5) After checking fuel leaks, wipe off soapy water from the pipe connection. (6) Remove 2 SSTs, and then remove the bolt, the nozzle leakage No.2 pipe and the gasket.
SST
SST
Nozzle Leakage No. 2 Pipe
New Gasket
A80119
Nozzle Leakage No. 2 Pipe Check Valve
(7)
Place a new gasket and reinstall the nozzle leakage No. 2 pipe with the check valve and the bolt. Torque: 8.8 NVm (90 kgfVcm, 79 in.Vlbf) for bolt 21 NVm (214 kgfVcm, 15 ftVlbf) for check valve HINT: Do not disassemble the check valve on the engine. (8) Reconnect the fuel hose to the nozzle leakage No. 2 pipe. 19. (a) (b) (c) (d) INSTALL CYLINDER HEAD COVER SUBASSY Remove any old packing (FIPG) material. Apply seal packing to the cylinder head. Seal packing: Part No. 0882600080 or equivalent Install the gasket to the cylinder head cover. Install the cylinder head cover with the 10 bolts. Torque: 13 NVm (135 kgfVcm, 9.7 ftVlbf)
New Gasket
A79146
:Seal Packing
A09663
1164
20. (a) 21.
INSTALL NOZZLE HOLDER SEAL Install new 4 nozzle holder seals. INSTALL TIMING BELT NO.2 COVER (See page 14307)
30 cm (11.81 in.)
SST
A79147
22. INSTALL INJECTION PIPE SUBASSY NO.1 NOTICE: S In case of having the injectors replaced, must replace the injection pipes, too. S 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. (c) Using SST, tighten the nut of the injection pipe to the common rail. SST 0902312700 Torque: 42 NVm (428 kgfVcm, 31 ftVlbf) for a used pipe using SST 46 NVm (469 kgfVcm, 34 ftVlbf) for a used pipe not using SST 31 NVm (316 kgfVcm, 23 ftVlbf) for a new pipe using SST 34 NVm (347 kgfVcm, 25 ftVlbf) for a new pipe not using SST HINT: S Use a torque wrench with a fulcrum length of 30 cm (11.81 in.) S Check if the used pipe has deflection or is installed properly after injection pipe is reassembled. If there is deflection 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 injector. SST 0902312700 Torque: 42 NVm (428 kgfVcm, 31 ftVlbf) for a used pipe using SST 46 NVm (469 kgfVcm, 34 ftVlbf) for a used pipe not using SST 31 NVm (316 kgfVcm, 23 ftVlbf) for a new pipe using SST 34 NVm (347 kgfVcm, 25 ftVlbf) for a new pipe not using SST HINT: S Use a torque wrench with a fulcrum length of 30 cm (11.81 in.) S Check if the used pipe has deflection or is installed properly after injection pipe is reassembled. If there is deflection 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 NVm (51 kgfVcm, 44 in.Vlbf)
1165
23.
INSTALL INJECTION PIPE SUBASSY NO.2 SST 0902312700
HINT: Perform the same procedures as injection pipe No. 1. 24. INSTALL INJECTION PIPE SUBASSY NO.3 SST 0902312700 HINT: Perform the same procedures as injection pipe No. 1. 25. INSTALL INJECTION PIPE SUBASSY NO.4 SST 0902312700 HINT: Perform the same procedures as injection pipe No. 1. 26. INSTALL AIR TUBE NO.1 (See page 14270) 27. INSTALL AIR CLEANER ASSY Torque: 7.0 NVm (71 kgfVcm, 62 in.Vlbf) 28. INSTALL ENGINE COVER NO.1 Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf) 29. INSTALL VACUUM RESERVOIR SUBASSY Torque: 8.3 NVm (85 kgfVcm, 74 in.Vlbf) 30. CHECK FOR FUEL LEAKS NOTICE: Under ACTIVE TEST mode, fuel pressure increases. Take precautions to prevent fuel from spraying on you or inside the engine compartment. HINT: During ACTIVE TEST mode, engine speed goes high and combustion noise becomes loud. (a) Check that there are no fuel leaks from any part of the fuel system at the engine stops. 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 part of the fuel system. 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 handheld tester to the DLC3. (f) Start the engine and push the handheld tester main switch ON. (g) Select the FUEL LEAK test of ACTIVE TEST mode on the handheld tester. (h) If you do not have the handheld tester, depress the accelerator pedal quickly and fully to increase the engine speed at maximum and keep it for 2 seconds. Repeat this operation several times. (i) Check that there are no leaks from any part 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.

Common Rail Assy (1Cd-Ftv) : Components

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Common Rail Assy (1Cd-Ftv) : Components

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1176

FUEL COMMON RAIL ASSY (1CDFTV)

COMMON RAIL ASSY (1CDFTV)

Radiator Support Opening Cover

Engine Cover No. 1

6.0 (61, 53 in.Vlbf)

Radiator Reserve Tank Assy

Nm (kgfcm, ftlbf) : Specified torque

AVENSIS REPAIR MANUAL (RM1018E)

* 31 (316, 23) 34 (347, 25) 5.0 (51, 44 in.Vlbf)

Injection Pipe Clamp No. 2 z Fuel Inlet Pipe Subassy

z Injection Pipe Subassy

* 31 (316, 23) 34 (347, 25)

Common Rail Assy

Intake Manifold Insulator No. 1

5.0 (51, 44 in.Vlbf) 43 (438, 32)

Fuel Hose No. 4

Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part * Use SST

REMOVE INJECTION PIPE SUBASSY SST 0902312700

AVENSIS REPAIR MANUAL (RM1018E)

REMOVE INJECTION PIPE SUBASSY NO.4 SST 0902312700

12. (a) (b)

AVENSIS REPAIR MANUAL (RM1018E)

AVENSIS REPAIR MANUAL (RM1018E)

20. 21. 22. 23. 24.

AVENSIS REPAIR MANUAL (RM1018E)

FUEL FILTER ASSY (1CDFTV)

6. (a) (b) (c) (d)

AVENSIS REPAIR MANUAL (RM1018E)

7. (a) (b) (c) 8. 9. 10.

AVENSIS REPAIR MANUAL (RM1018E)

FUEL INJECTOR ASSY (1AZFE)

7.0 (71, 62 in.Vlbf)

Mass Air Flow Meter Connector Air Cleaner Cap Subassy

Fuel Vapor Feed Hose No. 2

Nm (kgfcm, ftlbf) : Specified torque

AVENSIS REPAIR MANUAL (RM1018E)

z Fuel Injector Oring Fuel Injector Assy

Fuel Injector Connector

Fuel Delivery Pipe Subassy

Fuel Tube Subassy

Ventilation Hose No. 2

Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part

Retainer (at 4 places) Fuel Pipe Clamp

REMOVE FUEL DELIVERY PIPE SUBASSY Disconnect the ventilation hose.

AVENSIS REPAIR MANUAL (RM1018E)

(b) (b) (c) (c) (c)

Delivery Pipe No. 1 Spacer

REMOVE FUEL INJECTOR ASSY Pull out the 4 fuel injectors.

AVENSIS REPAIR MANUAL (RM1018E)

Fuel Pipe Clamp

10. 11. 12.

AVENSIS REPAIR MANUAL (RM1018E)

FUEL INJECTOR ASSY (1AZFSE)

Engine Room Cover Side

Clip Retainer Radiator Support Opening Cover

7.0 (71, 62 in.Vlbf)

Engine Cover Subassy No. 1 Fuel Vapor Feed Hose

Mass Air Flow Meter Connector

Air Cleaner Cap Subassy

Nm (kgfcm, ftlbf) : Specified torque

AVENSIS REPAIR MANUAL (RM1018E)