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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Fuel System (A25A-FXS) - Service Information (1 Of 2)) >> FUEL INJECTOR (for Port Injection) >> 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. REMOVE EGR VALVE ASSEMBLY 

    Refer to REMOVAL [11/2023 - ]

  7. REMOVE NO. 2 WATER BY-PASS PIPE 

    Refer to PROCEDURE - Step 8

  8. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the fuel pipe clamp from the fuel tube connector.
      GTY760014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tube sub-assembly from the fuel pump assembly and fuel delivery pipe sub-assembly.
      GTY880704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [11/2023 - ]

  9. 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.
        GTY880697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. for Cylinder Head Cover Sub-assembly Connection Type:
      1. Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.
        GTY1001860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Union Nut
        Bolt
      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.
  10. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 

    Refer to REMOVAL [11/2023 - ]

  11. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 
    1. Disconnect the No. 5 engine wire connector.
      GTY760009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and fuel delivery pipe sub-assembly with the 4 port fuel injector assemblies from the cylinder head sub-assembly.
      GTY773619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If fuel intrudes into the combustion chamber, there may be adverse effects to the engine main body.
      • Be careful not to drop the port fuel injector assemblies when removing the fuel delivery pipe sub-assembly.
  12. REMOVE NO. 1 DELIVERY PIPE SPACER 
    1. Remove the 2 No. 1 delivery pipe spacers from the cylinder head sub-assembly.
      GTY760008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE INJECTOR VIBRATION INSULATOR 
    1. Remove the 4 injector vibration insulators from the cylinder head sub-assembly.
      GTY760011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE NO. 5 ENGINE WIRE 
    1. Disconnect the 4 port fuel injector assembly connectors and No. 2 fuel pressure sensor connector.
      GTY771589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps to remove the No. 5 engine wire from the fuel delivery pipe sub-assembly.
  15. REMOVE PORT FUEL INJECTOR ASSEMBLY 
    1. Pull the 4 port fuel injector assemblies out of the fuel delivery pipe sub-assembly.
      GTY754430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from each port fuel injector assembly.
      GTY754415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Attach a tag or label with the corresponding cylinder number to each port fuel injector assembly so that they can be installed to their original locations.
      NOTE:

      Cover the port fuel injector assemblies with plastic bags to prevent damage and contamination.

      GTY766507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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