A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL; 2019 - 2021 MY Avalon HV [04/2018

Last Modified: 08-21-2023	6.11:8.1.0	Doc ID: RM100000001B4LI
Model Year Start: 2019	Model: Avalon HV	Prod Date Range: [04/2018 - 08/2021]
Title: A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL; 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during port fuel injector assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
*: When performing learning using the Techstream. Click here
Auxiliary battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane Departure Alert System (w/ Steering Control)
		Pre-collision System
		Intelligent Clearance Sonar System*
		Lighting System (for HV Model with Cornering Light)
	Memorize steering angle neutral point	Parking Assist Monitor System
	Memorize steering angle neutral point	Panoramic View Monitor System
Replacement of port fuel injector assembly Replacement of throttle body with motor assembly Cleaning the deposits from the throttle body with motor assembly Replacement of EGR valve assembly Gas leak from exhaust system is repaired	Inspection after repair	Poor idle, etc. Engine start function, etc.

CAUTION:

Never perform work on fuel system components near any possible ignition sources.
Vaporized fuel could ignite, resulting in a serious accident.
Do not perform work on fuel system components without first disconnecting the cable from the negative (-) auxiliary battery terminal.
Sparks could cause vaporized fuel to ignite, resulting in a serious accident.
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.

NOTICE:

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. PRECAUTION

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

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2. DISCHARGE FUEL SYSTEM PRESSURE

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3. REMOVE LUGGAGE TRIM SERVICE HOLE COVER

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4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

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5. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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6. REMOVE EGR VALVE ASSEMBLY

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7. REMOVE NO. 2 WATER BY-PASS PIPE

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8. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Remove the fuel pipe clamp from the fuel tube connector.

(b) Disconnect the fuel tube sub-assembly from the fuel delivery pipe sub-assembly.

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9. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

CAUTION:

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.

(a) Disconnect the ignition coil assembly connector.

(b) 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.

	Union Nut
	Bolt

(2) Using an 8 mm socket wrench, remove the bolt.

(d) Loosen the 2 bolts of the fuel pump assembly.

(e) Remove the No. 1 fuel pipe sub-assembly from the fuel delivery pipe and fuel pump assembly.

10. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Disconnect the No. 5 engine wire connector.

(b) Remove the 2 bolts and fuel delivery pipe sub-assembly with the 4 port fuel injector assemblies from the cylinder head sub-assembly.

NOTICE:

Be careful not to drop the port fuel injector assemblies when removing the fuel delivery pipe sub-assembly.

11. REMOVE NO. 1 DELIVERY PIPE SPACER

(a) Remove the 2 No. 1 delivery pipe spacers from the cylinder head sub-assembly.

12. REMOVE INJECTOR VIBRATION INSULATOR

(a) Remove the 4 injector vibration insulators from the cylinder head sub-assembly.

13. REMOVE NO. 5 ENGINE WIRE

(a) Disconnect the 4 port fuel injector assembly connectors and fuel pressure sensor connector.

(b) Disengage the 2 clamps to remove the No. 5 engine wire from the fuel delivery pipe sub-assembly.

14. REMOVE PORT FUEL INJECTOR ASSEMBLY

(a) Pull the 4 port fuel injector assemblies out of the fuel delivery pipe sub-assembly.

(b) Remove the O-ring from each port fuel injector assembly.

(c) 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.

NOTICE:

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