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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 Direct 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 INTAKE MANIFOLD 

    Refer to REMOVAL [10/2021 - ]

  6. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the fuel pipe clamp from the fuel tube connector.
      GTY836024Courtesy 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 - ]

  7. 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.
        GTY880699Courtesy 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.
  8. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 

    Refer to REMOVAL [11/2023 - ]

  9. REMOVE FUEL DELIVERY PIPE 
    NOTE:

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

    1. Disconnect the fuel pressure sensor connector.
      GTY760005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp to disconnect the sensor wire from the fuel delivery pipe.
    3. Disconnect the 4 direct fuel injector assembly connectors.
      GTY760007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure to disconnect the connectors carefully.

    4. Remove the 4 bolts and fuel delivery pipe with the 4 direct fuel injector assemblies from the cylinder head sub-assembly.
      GTY760006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If fuel intrudes into the combustion chamber, there may be adverse effects to the engine main body.
      • Make sure not to touch or strike the tips of the direct fuel injector assemblies.
      • Pull and remove the fuel delivery pipe in a straight line without tilting it.
  10. REMOVE DIRECT FUEL INJECTOR ASSEMBLY 
    1. Secure the fuel delivery pipe in a vise between aluminum plates and pull out the 4 direct fuel injector assemblies.
      GTY755577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Pull and remove each direct fuel injector assembly in a straight line to avoid damaging the seal surface of the fuel delivery pipe O-ring.
      • After removing the direct 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 direct fuel injector assembly so that they can be installed to their original locations.
      • Cover the tip of each direct fuel injector assembly to prevent it from being damaged.
    2. Remove the nozzle holder clamp from each direct fuel injector assembly.
    3. Using needle nose pliers, remove the No. 3 fuel injector back-up ring from each direct fuel injector assembly.
      NOTE:

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

    4. Remove the O-ring and No. 1 fuel injector back-up ring from each direct fuel injector assembly.
    5. Remove the C-ring and injector vibration insulator from each direct fuel injector assembly.
  11. REMOVE FUEL INJECTOR SEAL 
    1. Using the tip of needle nose pliers, pinch and pull the fuel injector seal at several points to stretch it.
      GTY771587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Excessively pinching the fuel injector seal may damage the groove of the direct fuel injector assembly.
      • If a direct fuel injector assembly is dropped or the tip of the direct fuel injector assembly is struck, replace it with a new one.
    2. Remove the fuel injector seal from each direct fuel injector assembly.
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