Replacing fuel injectors (1CD-FTV) [Toyota Corolla Verso-AR10]

Note: If a fault occurs and the engine ECU registers an incorrect injector correction code, the engine may start to jerk or idle rough. This may also cause engine failure and shorten the life of the engine.

Note: To optimize fuel injection performance, the engine ECU adjusts the injection duration for each cylinder. The engine ECU stores and uses injector correction values, which are indicated on the top of the injector as a 30-character alphanumeric code.

Note: When replacing an injector, the correction code of the new injector is entered into the engine ECU. When replacing the engine ECU, the correction codes of all injectors must be entered into the new ECU.

Note: After replacing the engine ECU, DTC P1601 will be displayed when the ignition is turned on. The injector correction codes must be registered in the engine ECU. To clear the DTC, first register the correction codes, then turn off the ignition and wait at least 30 seconds.

Disconnect the negative battery terminal.

Removal the vacuum receiver assembly

Disconnect the 2 vacuum hoses and connector.



Remove 2 bolts and vacuum receiver (fig. 2.525).

Remove the windshield wiper arm cover.

Remove the left windshield wiper arm and blade assembly.

Remove the right windshield wiper arm and blade assembly.

Remove the seal from the upper edge of the engine compartment bulkhead.

Remove the upper right air vent fairing.

Remove the upper left air vent fairing.

Remove the windshield wiper drive motor with the rod assembly.

Remove the upper outer hood panel.

Remove the radiator shroud hole cover.

Remove the upper engine cover No.1.

Remove the air filter with the air duct assembly.

Remove the battery.

Remove the lower left engine shield.

Remove air duct #1.

Removal high pressure fuel pipes

Remove 2 nuts and disconnect 2 upper high pressure fuel line clamps from the intake manifold.

Using SST, disconnect the high pressure fuel line from the common rail fuel line.

Using SST, disconnect the high pressure fuel line from the injector.

After removing the high pressure fuel pipe, cover the common rail fuel line with vinyl tape and cover the injector inlet with vinyl tape or a plastic bag to prevent dirt and foreign particles from entering.



Remove the high pressure fuel lines.

Remove timing belt drive cover No.2.

Using a screwdriver, remove the 4 injector sealing rings from the cylinder head.

Removal the cylinder head cover

Remove 10 bolts, cylinder head cover and gasket (fig. 2.526).

Removal the fuel return line assembly

Remove the hollow union bolt and 4 hollow bolts, then remove the fuel return line and 5 gaskets (fig. 2.527).

Note: When removing, place a rag under the fuel return line to prevent any fuel remaining in the line from spilling onto the cylinder head.

Remove 4 bolts, 4 washers and 4 injector body retainers.

Remove the fuel injector assembly.

Note: Each injector has its own fuel injection characteristics. When removing the injectors, arrange them in the order so that they can be installed in their original places during assembly.

Remove 4 injectors from the cylinder head.



Remove the sealing rings and spacers from the injectors (fig. 2.528).

Remove 4 injector seats from the cylinder head.

Register injector correction codes (in case of replacing injectors with new ones).

Installing the injectors as a whole

Install 4 injector seats into the cylinder head.

Install spacers and sealing rings on the injectors.

Lubricate the injector sealing rings with engine oil.

Install the injectors into the cylinder head.

Note: Insert the injectors into the injector sockets.

Install the injector housing retainers as shown in Figure 2.529.

Hand tighten the camshaft bearing cap bolt to secure the injector body retainer.

Note: Make sure the washers are installed in the correct position.

Note: When tightening the injector body retainer mounting bolt, make sure that the parts are positioned correctly.

Note: Lubricate the threads of the injector housing retainer bolts with engine oil.

Install high pressure fuel pipes No.1, No.2, No.3 and No.4 onto the injectors, then tighten the mounting nuts by hand.

Install 5 new gaskets and fuel return line #1. Hand tighten the 4 hollow bolts.

Tighten the 4 injector housing retaining bolts.

Tightening torque: 26 Nm.

Remove 4 high pressure fuel pipes.

Installing the Fuel Return Drain Pipe Assembly

Install the fuel return line and 5 new gaskets.

[The text is quoted from the source website: TOYOTAMAN.ru]

Note: Make sure that the shims are installed in the correct position. The shims are installed so that the protrusion is located within the limits shown in Figure 2.530.

Lubricate the 4 hollow bolts and the hollow connecting bolt-nipple with engine oil.

Tighten the 4 hollow bolts and the hollow connecting bolt-nipple by hand.

Tighten the 4 hollow bolts and the hollow connecting bolt-nipple to the specified torque.

Tightening torque: 18 Nm – hollow bolts, 22 Nm – hollow connecting bolt-nipple.

Check for fuel leaks at the fuel return line connection.

Disconnect the fuel line, then remove the bolt, check the valve, fuel return line No.2 and gasket.

Using SST, tighten the bolt, install the #2 fuel return line and gasket into the cylinder head.

Tightening torque: 8.8 Nm – bolt, 21 Nm – SST.

To check for leaks, lubricate with soapy water (or other suitable liquid) connection point for fuel return line No.2.



Use SST (turbocharger pressure gauge). Connect the SST to the injector at the connection point of the fuel return line No.2. Then apply a pressure of 100 kPa for 60 s to ensure that there are no air bubbles at the connection point of the line (fig. 2.531).

After checking for leaks, wipe off the soap solution from the pipe connection point.



Remove 2 SST, then remove bolt, fuel return line #2 and gasket.



Install a new gasket and reinstall the fuel return line #2 together with the check valve and secure the parts with the bolt (fig. 2.532).

Tightening torque: 8.8 Nm – bolt, 21 Nm – check valve.

Caution! Do not disassemble the check valve on the engine under any circumstances.

Connect the fuel line to the fuel return line No.2.

Installing the cylinder head cover

Remove any remaining old sealant (FIPG).



Apply sealant to the cylinder head (fig. 2.533).

Install the gasket on the cylinder head cover.

Install the cylinder head cover and secure with 10 bolts.

Tightening torque: 13 Nm.



Install 4 new fuel supply line seals.

Install timing belt drive cover No.2.

Install high pressure fuel lines.

Note: When replacing injectors, the high pressure fuel lines should also be replaced.

Note: Tubes should be installed on an engine that has cooled to room temperature or below.

Install the 2 lower high pressure fuel line retainers to the intake manifold.

Remove the plastic bag from the injector and the vinyl tape from the Common Rail fuel line.

Install the new high pressure fuel line without securing it.

Using SST, tighten the high pressure fuel pipe to common rail fuel pipe fastening nut.

Tightening torque: 31 Nm with SST, 34 Nm without SST.

Note: Use a torque wrench with a lever length of 30 cm.

Note: After installing the high pressure fuel pipes, make sure they are not deformed and installed correctly. If the pipes are deformed or cannot be installed correctly, replace them with new ones.

Using SST, tighten the nuts securing the high pressure fuel lines to the injectors.

Tightening torque for old tubes: 42 Nm with SST, 46 Nm without SST; for new tubes: 31 Nm with SST, 34 Nm without SST.

Install 2 upper high pressure fuel line clamps to the intake manifold.

Tightening torque: 5.0 Nm.

Install air duct #1.

Install the battery.

Install the air filter with the air duct assembly.

Install the upper engine cover #1.

Install the upper outer hood panel.

Install the windshield wiper drive motor with the rod assembly.

Install the right windshield wiper arm and blade assembly.

Install the left windshield wiper arm and blade assembly.

Install the vacuum receiver and secure with 2 bolts.

Tightening torque: 8.3 Nm.

Attach 2 vacuum hoses and connector.

Connect the negative terminal to the battery terminal.

Tightening torque: 5.4 Nm.

Check for fuel leaks.

Note: Fuel pressure increases in active diagnostic mode. Take measures to prevent fuel from splashing onto people or engine compartment parts.

Note: In Active Diagnostic mode, the engine speed increases and the combustion noise becomes louder.

Make sure there are no fuel leaks from all components of the fuel system after stopping the engine.

If a fuel leak is detected, it should be repaired by replacing the parts with new ones.

Make sure there are no fuel leaks from any fuel system components during operation or when cranking the engine with the starter.

If fuel leaks are detected on individual parts, the parts should be replaced with new ones.

Disconnect the fuel hose from the Common Rail fuel line.

Check for fuel leaks from the return line with the engine running.

If there is a fuel leak, replace the Common Rail fuel line.

Connect the Hand-Held Diagnostic Tool II to the DLC3 diagnostic connector.

Start the engine, then turn on the handheld diagnostic tool II.

Select the device mode: Powertrain Engine and ECT/ Active Test/ Fuel Leak Test.

If the check is performed without the portable diagnostic tool II, press the accelerator pedal sharply to increase the engine speed to the maximum value and maintain it for 2 seconds. Repeat this operation several times.

Make sure the fuel system is tight.

Note: The permissible leakage rate through the return drain line is less than 10 cm³ of fuel per minute.

Note: If a fuel leak is detected, it should be repaired by replacing the parts with new ones.

Note: Connect the fuel hose to the Common Rail fuel line.