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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 19 (Fuel System (A25A-FXS) - Service Information (2 Of 2)) >> FUEL PUMP (for High Pressure) >> Removal [11/2023 - ] >> Procedure

Removal [11/2023 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 
    NOTE:

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

    Refer to BEFORE DISCONNECTING BATTERY [11/2023 - ]

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [11/2023 - ]

  3. REMOVE BATTERY SERVICE HOLE COVER 

    Refer to PROCEDURE - Step 4

  4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 3

  5. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to REMOVAL [09/2020 - ]

  6. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the fuel pipe clamp from the fuel tube connector.
      GTY763614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tube sub-assembly from the fuel pump assembly and fuel delivery pipe sub-assembly.
      GTY935526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [11/2023 - ]

  7. REMOVE NO. 2 WATER BY-PASS PIPE 
    1. Disengage the clamp to disconnect the HV air conditioning wire.
      GTY763612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 8 water by-pass hose from the No. 2 water by-pass pipe.
      GTY763613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using an 8 mm socket wrench, remove the 2 bolts (A) and separate the No. 2 water by-pass pipe from the intake manifold.
      GTY752505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt (B) and No. 2 water by-pass pipe from the cylinder block sub-assembly.
  8. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY 
    WARNING:

    To prevent serious injury due to fuel spray from the high-pressure fuel lines, always discharge fuel system pressure before removing any fuel system components.

    1. Disconnect the ignition coil connector.
      GTY814962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for EGR Valve Bracket Connection Type:
      1. Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.
        GTY944880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Union Nut
        Bolt
      2. Using an 8 mm socket wrench, remove the bolt.
    3. for Cylinder Head Cover Sub-assembly Connection Type:
      1. GTY1001727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Union Nut
        Bolt

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

      2. Using an 8 mm socket wrench, remove the bolt.
    4. Loosen the 2 bolts of the fuel pump assembly.
      GTY880698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the No. 1 fuel pipe sub-assembly from the fuel delivery pipe and fuel pump assembly.
  9. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
    NOTE:

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

    1. Disconnect the fuel pump assembly connector.
      GTY880801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts, fuel pump assembly and fuel pump flange from the No. 4 camshaft bearing cap.
      GTY880802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring from the fuel pump assembly.
      GTY754529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the fuel pump lifter assembly from the fuel pump lifter guide.
      GTY880803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the fuel pump spacer gasket from the cylinder head cover sub-assembly and No. 4 camshaft bearing cap.
      GTY880797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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