Toyota Yaris: Engine Unit / Installation

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. INSTALL TIMING GEAR COVER INSULATOR

(a) Install the timing gear cover insulator to the cylinder blocke sub-assembly.

2. INSTALL NO. 3 CYLINDER BLOCK INSULATOR

(a) Install the No. 3 cylinder block insulator to the oil pan sub-assembly.

3. INSTALL INTAKE PIPE OR HOSE STAY

(a) Install the intake pipe or hose stay to the cylinder head cover sub-aseembly with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

4. INSTALL FUEL HOSE BRACKET

(a) Install the fuel hose bracket to the cylinder head cover sub-aseembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

5. INSTALL ENGINE COVER BRACKET

(a) Install the engine cover bracket to the vacuum pump bracket with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

6. INSTALL ENGINE COVER JOINT

(a) Install the engine cover joint to the cylinder head cover sub-aseembly and vacuum pump bracket.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

7. INSTALL IGNITION COIL ASSEMBLY

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8. INSTALL VACUUM REGULATING VALVE ASSEMBLY

(a) Install the vacuum regulating valve assembly to the cylinder head cover sub-assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

9. INSTALL VENTILATION HOSE

(a) Connect the No. 2 ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.

(b) Engage the clamp.

10. INSTALL SENSOR WIRE

(a) Install the sensor wire to the cylinder head sub-assembly and cylinder block sub-aseembly with the 2 bolts. Torque: Bolt (A) : 10 N·m {102 kgf·cm, 7 ft·lbf} Bolt (B) : 21 N·m {214 kgf·cm, 15 ft·lbf}

11. INSTALL NO. 2 CYLINDER BLOCK INSULATOR

(a) Install the No. 2 cylinder block insulator to the cylinder block sub-assembly.

12. INSTALL FUEL INJECTOR SEAL

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13. INSTALL FUEL INJECTOR ASSEMBLY

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14. INSTALL NO. 6 ENGINE WIRE

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15. INSTALL FUEL DELIVERY PIPE

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16. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY

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17. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY

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18. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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19. INSTALL INJECTOR VIBRATION INSULATOR

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20. INSTALL FUEL DELIVERY SPACER

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21. INSTALL FUEL DELIVERY PIPE (for Low Pressure)

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22. INSTALL NO. 1 DELIVERY PIPE SPACER

(a) Install the No. 1 fuel delivery spacer to the cylinder head sub-asembly.

23. INSTALL FUEL DELIVERY GUARD

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24. INSTALL OIL LEVEL GAUGE GUIDE

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25. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY

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26. INSTALL FUEL TUBE SUB-ASSEMBLY

(a) Install the fuel tube sub-assembly

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(b) Install the bolt.

(c) Install the fuel pipe clamp to the fuel tube connector.

27. INSTALL NO. 7 ENGINE WIRE

(a) Connect the 2 connectors and install the No. 7 engine wire.

(b) Engage the clamp.

28. INSTALL WATER BY-PASS PIPE

(a) Install the water by-pass pipe to the engine assembly and slide the clip to secure it.

(b) Install the bolt and nut.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

29. INSTALL INTAKE MANIFOLD

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30. INSTALL INTAKE AIR CONNECTOR BRACKET

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31. INSTALL NO. 2 ENGINE COVER BRACKET

(a) Install the No. 2 engine cover bracket to the intake manifold with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

32. INSTALL NO. 6 ENGINE WIRE

(a) Engage the 5 clamps and connect the No. 6 engine wire.

33. INSTALL PURGE VALVE (PURGE VSV)

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34. INSTALL NO. 2 TURBO INSULATOR

(a) Install the No. 2 turbo insulator to the cylinder brock sub-assembly with the 2 bolts. Torque: Bolt (A) : 21 N·m {214 kgf·cm, 15 ft·lbf} Bolt (B) : 30 N·m {306 kgf·cm, 22 ft·lbf}

35. INSTALL TURBOCHARGER SUB-ASSEMBLY

(a) Install the turbocharger sub-aseembly to the cylinder head sub-aseembly wuth the 7 nuts. Torque: Nut (B) : 44.3 N·m {452 kgf·cm, 33 ft·lbf}

(b) Connect the No. 1 turbo water pipe sub-assembly with the 2 bolts.

Torque:

Bolt (A) :

13 N·m {133 kgf·cm, 10 ft·lbf}

Bolt (C) :

35 N·m {357 kgf·cm, 26 ft·lbf}

(c) Install the inlet turbo oil pipe union bolt.

Torque:

Bolt (C) :

35 N·m {357 kgf·cm, 26 ft·lbf}

(d) Connect the outlet turbo oil pipe with the 2 bolts.

Torque:

Bolt (D) :

13 N·m {133 kgf·cm, 10 ft·lbf}

36. INSTALL NO. 1 TURBO INSULATOR

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37. INSTALL NO. 4 CYLINDER BROCK INSULATOR

(a) Install the No. 4 cylinder brock insulator with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

38. INSTALL DRIVE SHAFT BEARING BRACKET

(a) Install the drive shaft bearing bracket to the cylinder block sub-aseembly with the 3 bolts.

Torque:

63.7 N·m {650 kgf·cm, 47 ft·lbf}

39. INSTALL ENGINE HANGER BRACKET

(a) Install the engine hanger bracket to the cylinder head sub-assembly with the 2 bolts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

40. INSTALL INTAKE AIR PIPE

(a) Install the intake air pipe and tighten the hose clamp.

(b) Install the 3 bolts.

(c) Connect the ventilation hose.

(d) Connect the No. 2 vaccum transmitting hose.

(e) Connect the No. 1 vaccum transmitting hose.

41. INSTALL WATER BY-PASS HOSE ASSEMBLY

(a) Install the water by-pass hose assembly and slide the clip to secure it.

(b) Engage the clamp.

42. INSTALL NO. 4 WATER BY-PASS PIPE

(a) Install the No. 4 water by-pass pipe and slide the clip to secure it.

(b) Connect the No. 4 water by-pass pipe with the 3 bolts.

43. INSTALL NO. 3 WATER BY-PASS PIPE

(a) Install the No. 3 water by-pass pipe and slide the clip to secure it.

(b) Connect the No. 3 water by-pass pipe with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

44. INSTALL NO. 1 WATER BY-PASS PIPE

(a) Install the No. 1 water by-pass pipe and slide the clip to secure it.

(b) Connect the No. 1 water by-pass pipe with the bolt and nut.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

45. INSTALL NO. 1 TURBO WATER HOSE

(a) Install the No. 1 turbo water hose and slide the 2 clips to secure it.

46. INSTALL UNION TO CONNECTOR TUBE HOSE

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47. INSTALL NO. 3 VACUUM TRANSMITTING HOSE

(a) Install the No. 3 vacuum transmitting hose.

(b) Engage the 2 clamps.

48. INSTALL NO. 5 WATER BY-PASS HOSE

(a) Install the No. 5 water by-pass hose and slide the 2 clips to secure it.

(b) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

49. INSTALL NO. 6 WATER BY-PASS HOSE

(a) Install the No. 6 water by-pass hose and slide the 2 clips to secure it.

(b) Engage the clamp.

50. INSTALL NO. 5 AIR HOSE

(a) Install the No. 5 air hose and tighten the hose clamp.

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

51. INSTALL NO. 2 AIR HOSE

(a) Install the No. 2 air hose and tighten the hose clamp.

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

52. INSTALL OUTLET HEATER WATER HOSE

(a) Install the outlet heater water hose and slide the clip to secure it.

53. INSTALL INLET HEATER WATER HOSE

(a) Install the inlet heater water hose and slide the clip to secure it.

54. INSTALL FUEL TUBE SUB-ASSEMBLY

(a) Install the fuel tube sub-aseembly to the fuel pipe sub-aseembly.

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(b) Engage the clamp.

55. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY

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