Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001FHL8
Model Year Start: 2019 Model: RAV4 HV Prod Date Range: [11/2018 - 02/2019]
Title: A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): INSTALLATION; 2019 MY RAV4 HV [11/2018 - 02/2019]

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

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

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

PROCEDURE

1. INSTALL PORT FUEL INJECTOR ASSEMBLY

HINT:

Perform "Inspection After Repair" after replacing a port fuel injector assembly.

Click here 2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM (w/o Canister Pump Module): INITIALIZATION

(a) Apply a light coat of spindle oil or gasoline to 4 new O-rings, and install 1 to each port fuel injector assembly.

NOTICE:

Check that there is no damage or foreign matter on the groove of the port fuel injector assembly when installing the O-ring to each port fuel injector assembly.

(b) Install the 4 port fuel injector assemblies to the fuel delivery pipe sub-assembly.

NOTICE:

  • Make sure that the port fuel injector assembly is located within the stopper as shown in the illustration.
  • Check that the port fuel injector assembly installation holes of the fuel delivery pipe sub-assembly are not damaged and are free of foreign matter.
  • Make sure that the O-ring is not damaged, twisted or moved out of place when installing the port fuel injector assembly.

*a

Stopper

*b

Claw

2. INSTALL NO. 5 ENGINE WIRE

(a) Attach the 2 clamps and install the No. 5 engine wire to the fuel delivery pipe sub-assembly.

(b) Connect the 5 connectors to the 4 port fuel injector assemblies and fuel pressure sensor.

3. INSTALL INJECTOR VIBRATION INSULATOR

(a) Install 4 new injector vibration insulators to the cylinder head sub-assembly.

4. INSTALL NO. 1 DELIVERY PIPE SPACER

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

NOTICE:

Install the No. 1 delivery pipe spacers in the correct direction.

*a

Fuel delivery pipe sub-assembly Side

*b

Cylinder Head Sub-assembly Side

5. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Place the fuel delivery pipe sub-assembly to the cylinder head sub-assembly.

NOTICE:

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

(b) Install the fuel delivery pipe sub-assembly with the port fuel injector assemblies with the 2 bolts.

Torque:

28.5 N·m {291 kgf·cm, 21 ft·lbf}

(c) Connect the connector to the No. 5 engine wire.

6. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (FUEL): FUEL PUMP (for High Pressure): INSTALLATION+

7. INSTALL FUEL PUMP ASSEMBLY

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (FUEL): FUEL PUMP (for High Pressure): INSTALLATION+

8. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (FUEL): FUEL PUMP (for High Pressure): INSTALLATION+

9. CONNECT FUEL TUBE SUB-ASSEMBLY

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

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

(b) Install the fuel pipe clamp to the fuel tube connector.

10. INSTALL NO. 2 WATER BY-PASS PIPE

Click here 2019 - 2024 MY RAV4 HV [11/2018 -        ]; A25A-FXS (INTAKE / EXHAUST): INTAKE MANIFOLD: INSTALLATION+

11. INSTALL EGR VALVE ASSEMBLY

Click here 2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; A25A-FXS (EMISSION CONTROL): EGR VALVE: INSTALLATION

12. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (ENGINE CONTROL): THROTTLE BODY: INSTALLATION

13. CONNECT CABLE TO 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

14. INSTALL BATTERY HOLE COVER

Click here 2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: INSTALLATION+

15. INSTALL REAR NO. 2 FLOOR BOARD

Click here 2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: INSTALLATION+

16. INSTALL DECK BOARD ASSEMBLY

Click here 2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: INSTALLATION+

17. INSPECT FOR FUEL LEAK

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

18. PERFORM INITIALIZATION

(a) Perform "Inspection After Repair" after replacing a port fuel injector assembly.

Click here 2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM (w/o Canister Pump Module): INITIALIZATION