Toyota Yaris: Fuel Injector (for Port Injection) / 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 PORT FUEL INJECTOR ASSEMBLY

HINT:

Perform "Inspection After Repair" after replacing a fuel injector assembly.

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(a) Apply a light coat of spindle oil or gasoline to 3 new O-rings, and install one to each fuel injector assembly.

NOTICE:

Check that there is no damage or foreign matter on the groove of the fuel injector assembly when installing the O-ring to each fuel injector assembly.

(b) Install the 3 fuel injector assemblies to the fuel delivery pipe. NOTICE: Make sure that the fuel injector assembly is located within the stopper as shown in the illustration. Check that the fuel injector assembly installation holes of the fuel delivery pipe are not damaged and are free of foreign matter. Make sure that the O-ring is not damaged, twisted or moved out of place when installing the fuel injector assembly.

*a Claw *b Stopper

2. INSTALL NO. 5 ENGINE WIRE

(a) Engage the 2 clamps to install the No. 5 engine wire to the fuel delivery pipe.

(b) Connect the 4 connectors to the 3 fuel injector assemblies and fuel pressure sensor.

3. INSTALL INJECTOR VIBRATION INSULATOR

(a) Install 3 new injector vibration insulators to the cylinder head sub-assembly.

4. INSTALL FUEL DELIVERY SPACER

(a) Install the 2 fuel delivery spacers to the cylinder head sub-assembly.

5. INSTALL FUEL DELIVERY PIPE

(a) Place the fuel delivery pipe with the 3 fuel injector assemblies onto the cylinder head sub-assembly.

NOTICE:

Be careful not to drop the fuel injector assemblies when installing the fuel delivery pipe.

(b) Install the fuel delivery pipe with the fuel injector assemblies with the 2 bolts.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

6. INSTALL FUEL DELIVERY GUARD

(a) Temporarily install the fuel delivery guard.

(b) Install the 2 bolts and 2 nuts in the order shown in the illustration.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(c) Engage the engine wire clamp.

7. INSTALL OIL LEVEL GAUGE GUIDE

(a) Apply a light coat of engine oil to a new O-ring.

(b) Install the O-ring to the engine oil level guide.

(c) Install the engine oil level guide with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

8. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY

(a) Install the engine oil level gauge sub-assembly.

9. INSTALL NO. 4 WATER BY-PASS PIPE

(a) Install the No. 4 water by-pass pipe to the cylinder head sub-assembly with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

10. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

(a) Connect the No. 2 fuel tube sub-assembly to the fuel delivery pipe.

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11. INSTALL FUEL PIPE CLAMP

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

12. INSTALL ENGINE WIRE

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13. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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14. INSPECT FOR FUEL LEAK

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15. PERFORM INITIALIZATION

(a) Perform "Inspection After Repair" after replacing a fuel injector assembly.

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