Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001FHL7
Model Year Start: 2019 Model: RAV4 HV Prod Date Range: [11/2018 - 02/2019]
Title: A25A-FXS (FUEL): FUEL SYSTEM: ON-VEHICLE INSPECTION; 2019 MY RAV4 HV [11/2018 - 02/2019]

ON-VEHICLE INSPECTION

PROCEDURE

1. CHECK FUEL PUMP OPERATION AND INSPECT FOR FUEL LEAK

(a) Check fuel pump operation.

(1) Connect the Techstream to the DLC3.

(2) Turn the power switch on (IG).

NOTICE:

Do not start the engine.

(3) Turn the Techstream on.

(4) Enter the following menus: Powertrain / Engine / Active Test / Activate the Circuit Relay.

Powertrain > Engine > Active Test

Tester Display

Activate the Circuit Relay

(5) Check for pressure in the fuel tube sub-assembly from the fuel line. Check that sounds of fuel flowing from the fuel tank assembly can be heard. If no sounds can be heard, check the relay, fuel pump, ECM and wiring connectors.

(b) Inspect for fuel leaks.

(1) Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.

(c) Turn the power switch off.

(d) Disconnect the Techstream from the DLC3.

2. CHECK FUEL PRESSURE

(a) Discharge fuel system pressure.

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

(b) Measure the auxiliary battery voltage.

Standard voltage:

11 to 14 V

(c) Disconnect the cable from the negative (-) auxiliary battery terminal.

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Click here 2019 MY RAV4 RAV4 HV [11/2018 - 02/2019]; INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION

(d) Open the cover of the No. 1 fuel pipe clamp and remove the No. 1 fuel pipe clamp from the fuel tube connector.

Open

Pull

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

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

(f) Install SST (EFI fuel pressure gauge) as shown in the illustration.

SST: 09268-45101

09268-41250

09268-41260

09268-41280

09268-41500

09268-41700

95336-08070

*1

Fuel Tube Sub-assembly (Vehicle Side)

*a

SST (Hose Band)

*b

SST (T-joint)

*c

SST (Gauge)

*d

SST (Hose Joint)

*e

SST (Hose)

*f

SST (Fuel Tube Connector)

*g

Fuel Pipe (Vehicle Side)

(g) Wipe up any spilled fuel.

(h) Connect the cable to the negative (-) auxiliary battery terminal.

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Click here 2019 MY RAV4 RAV4 HV [11/2018 - 02/2019]; INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION

(i) Connect the Techstream to the DLC3.

(j) Turn the power switch on (IG).

NOTICE:

Do not start the engine.

(k) Turn the Techstream on.

(l) Enter the following menus: Powertrain / Engine / Active Test / Activate the Circuit Relay.

Powertrain > Engine > Active Test

Tester Display

Activate the Circuit Relay

(m) Measure the fuel pressure.

Standard fuel pressure:

294 to 833 kPa (3.0 to 8.5 kgf/cm2, 43 to 121 psi)

  • If the fuel pressure is less than the standard, check the fuel hoses and their connections, fuel pump, fuel filter and fuel main valve assembly.
  • If the result is not as specified, replace the fuel main valve assembly.

(n) Put the engine in Inspection Mode (Maintenance Mode).

Powertrain > Hybrid Control > Utility

Tester Display

Inspection Mode

(o) Start the engine.

(p) Measure the fuel pressure at idle.

Standard fuel pressure:

294 to 833 kPa (3.0 to 8.5 kgf/cm2, 43 to 121 psi)

HINT:

Refer to Standard Idle Speed.

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE: ON-VEHICLE INSPECTION+

(q) Stop the engine.

(r) Check that the fuel pressure remains as specified for 5 minutes.

Standard fuel pressure:

98 kPa (1.0 kgf/cm2, 14.2 psi) or more

If the result is not as specified, check the fuel pump, fuel main valve assembly and/or port fuel injector assemblies.

(s) After checking the fuel pressure, disconnect the cable from the negative (-) auxiliary battery terminal and carefully remove SST to prevent fuel from spraying.

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Click here 2019 MY RAV4 RAV4 HV [11/2018 - 02/2019]; INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION

(t) Connect the fuel tube sub-assembly to the fuel pipe.

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

(u) Install the No. 1 fuel pipe clamp to the fuel tube connector and close the cover of the No. 1 fuel pipe clamp.

(v) Inspect for fuel leaks.

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (FUEL): FUEL SYSTEM: ON-VEHICLE INSPECTION+

3. CHECK FUEL PRESSURE (for High Pressure)

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Turn the Techstream on.

(d) Put the engine in Inspection Mode (Maintenance Mode).

Powertrain > Hybrid Control > Utility

Tester Display

Inspection Mode

(e) Start the engine and warm it up until the engine coolant temperature is 75°C (167°F) or higher with all the accessories switched off.

(f) Enter the following menus: Powertrain / Engine / Data List / Engine Speed, Coolant Temperature, Fuel Pressure (High) and Injection Mode.

Powertrain > Engine > Data List

Tester Display

Engine Speed

Coolant Temperature

Fuel Pressure (High)

Injection Mode

(g) According to the display on the Techstream, read the Data List.

HINT:

During charge control, the engine speed is set at idle. Therefore, the engine speed will not increase when the accelerator pedal is depressed. In this case, read the Data List after charge control has completed.

Standard:

Techstream Display

Condition

Specified Condition

Fuel Pressure (High)
  • Shift position: P
  • A/C: Off
  • Engine warmed up
  • Engine Speed: 2500 rpm
  • Injection Mode: Direct

3000 to 25000 kPag

If the result is not as specified, check the fuel pump, fuel pump assembly, fuel pressure sensor and wire harnesses.

(h) Stop the engine.