Toyota Yaris: Fuel Pump (for High Pressure) / Removal

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (fuel) / Fuel Pump (for High Pressure) / 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 pump 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

Fuel pump assembly (for high pressure side)

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.

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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.

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3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

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4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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5. REMOVE FRONT NO. 1 VENTILATOR SEAL

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6. REMOVE WATER GUARD PLATE RH

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7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

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8. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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9. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

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10. DISCONNECT NO. 1 FUEL TUBE SUB-ASSEMBLY

(a) Disconnect the No. 1 fuel tube sub-assembly from the No. 2 fuel tube sub-assembly.

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11. REMOVE FUEL PIPE CLAMP

(a) Remove the fuel pipe clamp from the No. 2 fuel tube sub-assembly.

12. REMOVE NO. 2 FUEL TUBE SUB-ASSEMBLY

(a) Remove the bolt.

(b) Remove the No. 2 fuel tube sub-assembly from the fuel delivery pipe sub-assembly and fuel pump assembly.

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13. DISCONNECT NO. 8 WATER BY-PASS HOSE

(a) Slide the clip and disconnect the No. 8 water by-pass hose.

14. DISCONNECT NO. 1 WATER BY-PASS HOSE

(a) Slide the clip and disconnect the No. 1 water by-pass hose.

15. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

(b) Remove the bolt.

(c) Using an 8 mm socket wrench, loosen the 2 bolts of the fuel pump assembly.

(d) Remove the No. 1 fuel pipe sub-assembly from the fuel delivery pipe and fuel pump assembly.

16. DISCONNECT ENGINE WIRE

(a) Disconnect the 2 connectors.

(b) Remove the bolt.

(c) Disengage the clamp and disconnect the engine wire.

17. DISCONNECT NO. 1 VACUUM TRANSMITTING HOSE

(a) Disengage the 2 clamps and disconnect the No. 1 vacuum transmitting hose.

18. SEPARATE INTAKE AIR RESONATOR

(a) Remove the bolt and separate the intake air resonator from the fuel pump flange.

19. REMOVE FUEL PUMP ASSEMBLY

NOTICE:

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

(a) Remove the 2 bolts, fuel pump assembly and fuel pump flange from the cylinder head cover sub-assembly.

(b) Remove the O-ring from the fuel pump assembly.

(c) Remove the fuel pump lifter assembly from the fuel pump lifter guide.

(d) Remove the fuel pump spacer gasket from the cylinder head cover sub-assembly.

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    Categories

    Turning the Engine Off

    Stop the vehicle completely. Manual transaxle: Shift into neutral and set the parking brake.

    Automatic transaxle: Shift the selector lever to the P position and set the parking brake.

    Press the push button start to turn off the engine. The ignition position is off.

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