Toyota Yaris: Engine Unit / Removal

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (engine Mechanical) / Engine Unit / Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during engine unit removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

  • Engine assembly
  • Cylinder head sub-assembly
  • Camshaft (for intake or exhaust camshaft)
  • Camshaft timing gear assembly
  • Camshaft timing exhaust gear assembly
  • Fuel injector assembly
  • Fuel pump (for low pressure side)
  • Fuel pump assembly (for high pressure side)
  • Fuel pressure sensor (for low pressure side)
  • Fuel pressure sensor (for high pressure side)
  • Spark plug
  • Ignition coil assembly
  • Air intake system parts
  • Exhaust system parts
  • Turbocharger sub-assembly

Inspection after repair

  • Poor idle, etc.
  • Engine start function, etc.

PROCEDURE

1. REMOVE COMPRESSOR WITH PULLEY ASSEMBLY

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2. REMOVE FUEL TUBE SUB-ASSEMBLY

(a) Disengage the clamp.

(b) Remove the fuel tube sub-assembly from the fuel pipe sub-assembly.

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3. REMOVE HEATER WATER HOSE INLET

(a) Slide the clip and remove the heater water hose inlet from the No. 1 water by-pass pipe.

4. REMOVE HEATER WATER HOSE OUTLET

(a) Slide the clip and remove the heater water hose outlet from the No. 3 water by-pass pipe.

5. REMOVE NO. 2 AIR HOSE

(a) Loosen the hose clamp and remove the No. 2 air hose from the turbocharger sub-assembly.

6. REMOVE NO. 5 AIR HOSE

(a) Loosen the hose clamp and remove the No. 5 air hose from the air tube assembly.

7. REMOVE NO. 6 WATER BY-PASS HOSE

(a) Slide the 2 clips and separate the No. 6 water by-pass hose.

(b) Disengage the clamp and remove the No. 6 water by-pass hose from the No. 1 water hose clamp bracket.

8. REMOVE NO. 5 WATER BY-PASS HOSE

(a) Slide the 2 clips and separate the No. 5 water by-pass hose.

(b) Remove the bolt and No. 5 water by-pass hose from the crankshaft bearing cap assembly.

9. REMOVE NO. 3 VACUUM TRANSMITTING HOSE

(a) Disengage the 2 clamp and remove the No. 3 vacuum transmitting hose.

10. REMOVE UNION TO CONNECTOR TUBE HOSE

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11. REMOVE NO. 1 TURBO WATER HOSE

(a) Slide the 2 clips and remove the No. 1 turbo water hose.

12. REMOVE NO. 1 WATER BY-PASS PIPE

(a) Slide the clip and separate the water by-pass hose.

(b) Remove the bolt, nut and No. 1 water by-pass pipe.

13. REMOVE NO. 3 WATER BY-PASS PIPE

(a) Remove the bolt and separate the No. 3 water by-pass pipe.

(b) Slide the clip and remove the No. 3 water by-pass pipe.

14. REMOVE NO. 4 WATER BY-PASS PIPE

(a) Remove the 3 bolts and separate the No. 4 water by-pass pipe.

(b) Slide the clip and remove the No. 4 water by-pass pipe.

15. REMOVE WATER BY-PASS HOSE ASSEMBLY

(a) Disengage the clamp.

(b) Slide the 2 clips and remove the water by-pass hose assembly.

16. REMOVE E.F.I. VACUUM SENSOR ASSEMBLY

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17. REMOVE INTAKE AIR PIPE

(a) Separate the No.1 vaccum transmitting hose.

(b) Separate the No. 2 vaccum transmitting hose.

(c) Separate the ventilation hose.

(d) Remove the e3 bolts.

(e) Loosen the hose clamp and remove the intake air pipe from the .

18. REMOVE ENGINE HANGER BRACKET

(a) Remove the 2 bolts and engine hanger bracket from the cylinder head sub-assembly.

19. REMOVE DRIVE SHAFT BEARING BRACKET

(a) Remove the 3 bolts and drive shaft bearing bracket from the cylinder block sub-aseembly.

20. REMOVE NO. 4 CYLINDER BROCK INSULATOR

(a) Remove the 2 bolts and No. 4 cylinder brock insulator.

21. REMOVE NO. 1 TURBO INSULATOR

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22. REMOVE TURBOCHARGER SUB-ASSEMBLY

(a) Remove the 2 bolts and separate the outlet turbo oil pipe.

(b) Remove the inlet turbo oil pipe union bolt.

(c) Remove the 2 bolts and separate the No. 1 turbo water pipe sub-assembly.

(d) Remove the 7 nuts and turbocharger sub-aseembly from the cylinder head sub-aseembly.

23. REMOVE NO. 2 TURBO INSULATOR

(a) Remove the 2 bolts and No. 2 turbo insulator from the cylinder brock sub-assembly.

24. REMOVE PURGE VALVE (PURGE VSV)

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25. REMOVE NO. 6 ENGINE WIRE

(a) Disengage the 5 clamps and separate the No. 6 engine wire.

26. REMOVE NO. 2 ENGINE COVER BRACKET

(a) Remove the bolt and No. 2 engine cover bracket from the intake manifold.

27. REMOVE INTAKE AIR CONNECTOR BRACKET

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28. REMOVE INTAKE MANIFOLD

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29. REMOVE WATER BY-PASS PIPE

(a) Remove the bolt and nut.

(b) Slide the clip and remove the water by-pass pipe from the water inlet with thermostat sub-assembly.

30. REMOVE NO. 7 ENGINE WIRE

(a) Disengage the clamp.

(b) Disconnect the 2 connectors and remove the No. 7 engine wire.

31. REMOVE FUEL TUBE SUB-ASSEMBLY

(a) Remove the fuel pipe clamp from the fuel tube connector.

(b) Remove the bolt.

(c) Remove the fuel tube sub-assembly.

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32. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY

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33. REMOVE OIL LEVEL GAUGE GUIDE

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34. REMOVE FUEL DELIVERY GUARD

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35. REMOVE NO. 1 DELIVERY PIPE SPACER

(a) Remove the No. 1 delivery pipe spacer.

36. REMOVE FUEL DELIVERY PIPE (for Low Pressure)

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37. REMOVE FUEL DELIVERY SPACER

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38. REMOVE INJECTOR VIBRATION INSULATOR

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39. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

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40. REMOVE FUEL PUMP ASSEMBLY (ENGINE ROOM SIDE)

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41. REMOVE NO. 1 VENTILATION FLANGE SEPARATOR

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42. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (for High Pressure)

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43. REMOVE NO. 6 ENGINE WIRE

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44. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

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45. REMOVE FUEL INJECTOR SEAL

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46. REMOVE NO. 2 CYLINDER BLOCK INSULATOR

(a) Remove the No. 2 cylinder block insulator from the cylinder block sub-assembly.

47. REMOVE SENSOR WIRE

(a) Remove the 2 bolts and remove the sensor wire from the cylinder block sub-assembly.

48. REMOVE VENTILATION HOSE

(a) Disengage the clamp.

(b) Slide the clip and remove the ventilation hose from the cylinder head cover sub-assembly.

49. REMOVE VACUUM REGULATING VALVE ASSEMBLY

(a) Remove the 2 bolts and vacuum regulating valve assembly from the cylinder head cover sub-assembly.

50. REMOVE IGNITION COIL ASSEMBLY

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51. REMOVE ENGINE COVER JOINT

(a) Remove the 2 engine cover joints from the cylinder head cover sub-assembly.

52. REMOVE ENGINE COVER BRACKET

(a) Remove the bolt and engine cover bracket from the No. 1 vacuum pump bracket.

53. REMOVE FUEL HOSE BRACKET

(a) Remove the 2 bolts and fuel hose bracket form the cylinder head cover sub-assembly.

54. REMOVE INTAKE PIPE OR HOSE STAY

(a) Remove the 3 bolts and intake pipe or hose stay from the cylinder head cover sub-assembly.

55. REMOVE NO. 3 CYLINDER BLOCK INSULATOR

(a) Remove the No. 3 cylinder block insulator from the cylinder block sub-assembly.

56. REMOVE TIMING GEAR COVER INSULATOR

(a) Remove the timing gear cover insulator from the timing chain cover assembly.

    Components

    COMPONENTS ILLUSTRATION *1 FUEL TUBE SUB-ASSEMBLY *2 HEATER WATER HOSE INLET *3 HEATER WATER HOSE OUTLET *4 NO. 2 AIR HOSE *5 NO...

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