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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Engine Mechanical >> Fuel System >> Fuel System (2GR-FKS) - Service Information >> FUEL INJECTOR (for Direct Injection) >> Removal [12/2019 - 10/2022] >> Procedure

Removal [12/2019 - 10/2022]: Procedure

  1. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to REMOVAL [12/2019 - 10/2022] 

  2. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY 
    1. Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 2 fuel pipe sub-assembly.
      GTY887164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 2 fuel pipe sub-assembly from the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH.
  3. REMOVE FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH 
    1. Disconnect the No. 6 engine wire connector and No. 7 engine wire connector.
      GTY739814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps to disconnect the No. 6 engine wire connector and No. 7 engine wire connector.
      GTY726954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the fuel pressure sensor connector.
      GTY887165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt.
      GTY887166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the clamp to disconnect the No. 7 engine wire from the fuel delivery pipe with sensor assembly LH.
    6. Remove the 2 bolts, 2 nuts and fuel delivery pipe with sensor assembly LH with the 3 direct fuel injector assemblies from the cylinder head LH.
      GTY862768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
      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 with sensor assembly LH in a straight line without tilting it.
    7. Disconnect the 3 direct fuel injector assembly connectors.
      GTY669069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FUEL DELIVERY PIPE RH 
    1. Remove the bolt.
      GTY887161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp to disconnect the No. 6 engine wire from the fuel delivery pipe RH.
    3. Remove the 2 bolts, 2 nuts and fuel delivery pipe RH with the 3 direct fuel injector assemblies from the cylinder head sub-assembly.
      GTY873619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
      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 RH in a straight line without tilting it.
    4. Disconnect the 3 direct fuel injector assembly connectors.
      GTY684982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE DIRECT FUEL INJECTOR ASSEMBLY 
    1. Secure the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH in a vise between aluminum plates and pull out the 6 direct fuel injector assemblies.
      GTY635435Courtesy 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 with sensor assembly LH and fuel delivery pipe RH 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 with sensor assembly LH and fuel delivery pipe RH 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.
  6. 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.
      GTY550396Courtesy 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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