Toyota Yaris: Fuel Injector (for Port Injection) / Installation

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (fuel) / 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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    Inspection

    INSPECTION PROCEDURE 1. INSPECT FUEL INJECTOR ASSEMBLY (a) Check the resistance. (1) Measure the resistance according to the value(s) in the table below...

    Fuel Main Valve

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    Other information:

    Toyota Yaris XP210 (2020-2022) Reapir and Service Manual: System Diagram


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