A25A-FXS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL; 2022 MY Avalon HV [08/2021

Last Modified: 08-21-2023	6.11:8.1.0	Doc ID: RM100000001YO5O
Model Year Start: 2022	Model: Avalon HV	Prod Date Range: [08/2021 - ]
Title: A25A-FXS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL; 2022 MY Avalon HV [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 direct 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 Tracing Assist System
		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 direct fuel injector assembly Replacement of throttle body with motor assembly Cleaning the deposits from the throttle body with motor 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.

Click here

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.

Click here

2. DISCHARGE FUEL SYSTEM PRESSURE

Click here

3. REMOVE LUGGAGE TRIM SERVICE HOLE COVER

Click here

4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

Click here

5. REMOVE INTAKE MANIFOLD

Click here

6. 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.

7. REMOVE FUEL DELIVERY PIPE

NOTICE:

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

(a) Disconnect the fuel pressure sensor connector.

(b) Disengage the clamp to disconnect the sensor wire from the fuel delivery pipe.

NOTICE:

Make sure to disconnect the connectors carefully.

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

NOTICE:

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.

8. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

(a) Secure the fuel delivery pipe in a vise between aluminum plates and pull out the 4 direct fuel injector assemblies.

NOTICE:

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.

(b) Remove the nozzle holder clamp from each direct fuel injector assembly.

NOTICE:

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

(d) Remove the O-ring and No. 1 fuel injector back-up ring from each direct fuel injector assembly.

(e) Remove the C-ring and injector vibration insulator from each direct fuel injector assembly.

9. REMOVE FUEL INJECTOR SEAL

(a) Using the tip of needle nose pliers, pinch and pull the fuel injector seal at several points to stretch it.

NOTICE:

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.

(b) Remove the fuel injector seal from each direct fuel injector assembly.