Toyota Yaris: Fuel Injector (for Direct Injection) / Removal

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (fuel) / Fuel Injector (for Direct Injection) / 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 fuel injector assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

Replacement of fuel injector assembly

Inspection after repair

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

CAUTION:

  • Never perform work on fuel system components near any possible ignition sources.
  • Vaporized fuel could ignite, resulting in a serious accident.
  • Do not perform work on fuel system components without first disconnecting the cable from the negative (-) auxiliary battery terminal.
  • Sparks could cause vaporized fuel to ignite, resulting in a serious accident.

NOTICE:

  • After the ignition switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 120 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal.
  • This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

    Click here

HINT:

When the cable is disconnected/reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

  • Learning completes when vehicle is driven

    Effect/Inoperative Function When Necessary Procedures are not Performed

    Necessary Procedures

    Link

    Lane tracing assist system

    Drive the vehicle straight ahead at 35 km/h (22 mph) or more for 5 second or more.

    Pre-collision system

    Stop and start system

    Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)

  • Learning completes when vehicle is operated normally

    Effect/Inoperative Function When Necessary Procedures are not Performed

    Necessary Procedures

    Link

    Power door lock control system

    • Back door opener

    Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.

    Air conditioning system

    After the ignition switch is turned to ON, the servo motor standard position is recognized.

    -

PROCEDURE

1. DISCHARGE FUEL SYSTEM PRESSURE

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2. PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

Click here

3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

Click here

4. REMOVE INTAKE MANIFOLD

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5. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

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6. SEPARATE NO. 2 WATER BY-PASS PIPE

(a) Remove the 2 bolts to separate the No. 2 water by-pass pipe.

7. REMOVE FUEL DELIVERY PIPE

NOTICE:

When replacing the fuel delivery pipe, it is necessary to replace the No. 1 fuel pipe sub-assembly with a new one.

(a) Remove the 3 bolts and fuel delivery pipe with the 3 fuel injector assemblies from the cylinder head sub-assembly.

NOTICE:

  • Make sure not to touch or strike the tips of the fuel injector assemblies.
  • Pull and remove the fuel delivery pipe in a straight line without tilting it.

8. REMOVE NO. 6 ENGINE WIRE

(a) Disengage the 2 clamps.

(b) Disconnect the 3 fuel injector assembly connectors and remove the No. 6 engine wire from the fuel delivery pipe.

NOTICE:

Make sure to disconnect the connectors carefully.

9. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

(a) Secure the fuel delivery pipe in a vise between aluminum plates and pull out the 3 fuel injector assemblies.

NOTICE:

  • Pull and remove each fuel injector assembly in a straight line to avoid damaging the seal surface of the fuel delivery pipe O-ring.
  • After removing the fuel injector assemblies, remove any O-rings, No. 1 fuel injector back-up rings and No. 3 fuel injector back-up rings remaining on the fuel delivery pipe side.
  • Attach a tag or label with the corresponding cylinder number to each fuel injector assembly so that they can be installed to their original locations.
  • Cover the tip of each fuel injector assembly to prevent it from being damaged.

(b) Remove the nozzle holder clamp from each fuel injector assembly.

(c) Using needle nose pliers, remove the No. 3 fuel injector back-up ring from each fuel injector assembly.

NOTICE:

Do not damage the area that contacts the O-ring.

(d) Remove the O-ring and No. 1 fuel injector back-up ring from each fuel injector assembly.

(e) Remove the C-ring from each fuel injector assembly.

(f) Remove the injector vibration insulator from each fuel injector assembly.

10. REMOVE FUEL INJECTOR SEAL

(a) Using the tip of needle nose pliers, pinch and pull the fuel injector seal at several points to stretch it.

NOTICE:

  • Excessively pinching the fuel injector seal may damage the groove of the fuel injector assembly.
  • If a fuel injector assembly is dropped or the tip of the fuel injector assembly is struck, replace it with a new one.

(b) Remove the fuel injector seal from each fuel injector assembly.

    Components

    COMPONENTS ILLUSTRATION *1 FUEL INJECTOR ASSEMBLY *2 FUEL DELIVERY PIPE *3 FUEL INJECTOR SEAL *4 C-RING *5 NO. 3 FUEL INJECTOR BACK-UP RING *6 O-RING *7 NO...

    Inspection

    INSPECTION PROCEDURE 1. INSPECT FUEL INJECTOR ASSEMBLY NOTICE: This inspection is for checking the fuel injector assembly for an open or short. Because the fuel injector assembly of this vehicle is a high-pressure type, fuel injection volume cannot be checked...

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    Categories

    Break-In Period

    No special break-in is necessary, but a few precautions in the first 600 miles (1,000 km) may add to the performance, economy, and life of the vehicle.

    Do not race the engine. Do not maintain one constant speed, either slow or fast, for a long period of time. Do not drive constantly at full-throttle or high engine rpm for extended periods of time. Avoid unnecessary hard stops. Avoid full-throttle starts.

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