Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001FHLW
Model Year Start: 2019 Model: RAV4 HV Prod Date Range: [11/2018 - 02/2019]
Title: A25A-FXS (FUEL): FUEL PUMP (for High Pressure): 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. TEMPORARILY INSTALL FUEL PUMP ASSEMBLY

NOTICE:

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

HINT:

Perform "Inspection After Repair" after replacing the fuel pump 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) Turn the crankshaft pulley until the flat of the camshaft faces the fuel pump lifter assembly.

HINT:

This prevents the camshaft nose from pushing up the fuel pump lifter assembly when installing the fuel pump assembly.

*1

Fuel Pump Assembly

*2

Fuel Pump Lifter Assembly

*3

No. 2 Camshaft

*a

Correct

*b

Incorrect

(b) Apply 30 cc (1.8 cu.in.) of engine oil to the pump drive cam.

*1

Cylinder Head Cover Sub-assembly

*2

Fuel Pump Spacer Gasket

*a

Pump Drive Cam (Engine Oil Application Area)

*b

Fuel Pump Lifter Assembly (Engine Oil Application Area)

(c) Apply engine oil to the fuel pump lifter assembly.

(d) Install a new fuel pump spacer gasket to the cylinder head cover sub-assembly.

(e) Apply engine oil to the inside of the fuel pump lifter guide and the outside of the fuel pump lifter assembly.

*a

Fuel Pump Lifter Assembly (Engine Oil Application Area)

*b

Fuel Pump Lifter Guide (Engine Oil Application Area)

*c

Stopper Key

*d

Key Groove

(f) Set the fuel pump lifter assembly on the fuel pump lifter guide as shown in the illustration.

HINT:

Align the stopper key of the fuel pump lifter assembly with the key groove of the fuel pump lifter guide.

(g) Apply engine oil to a new O-ring and install it to the fuel pump assembly.

NOTICE:

Do not damage the O-ring.

(h) Set the fuel pump flange and fuel pump assembly on the cylinder head cover sub-assembly as shown in the illustration.

*1

Fuel Pump Assembly

*2

Fuel Pump Flange

(i) Temporarily install the fuel pump assembly with the 2 bolts, leaving some allowance for left and right movement.

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

NOTICE:

Do not damage the seals of the union nuts of the No. 1 fuel pipe sub-assembly.

(a) Temporarily install the bolt.

(b) Temporarily install the No. 1 fuel pipe sub-assembly to the fuel delivery pipe and tighten the union nut by hand.

(c) Temporarily install the No. 1 fuel pipe sub-assembly to the fuel pump assembly and tighten the union nut by hand.

3. INSTALL FUEL PUMP ASSEMBLY

(a) Tighten the 2 bolts.

Torque:

28.5 N·m {291 kgf·cm, 21 ft·lbf}

(b) Connect the connector to the fuel pump assembly.

4. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

HINT:

  • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

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

  • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

*a

Torque Wrench Fulcrum Length

(b) Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

HINT:

  • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

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

  • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

*a

Torque Wrench Fulcrum Length

(c) Connect the No. 1 fuel pipe sub-assembly to the cylinder head sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Connect the connector to the ignition coil assembly.

5. INSTALL NO. 2 WATER BY-PASS PIPE

(a) Temporarily install the No. 2 water by-pass pipe to the cylinder block sub-assembly with the bolt (B).

(b) Temporarily install the No. 2 water by-pass pipe to the intake manifold with the 2 bolts (A).

(c) Tighten the bolt (B).

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(d) Tighten the 2 bolts (A).

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(e) Connect the No. 8 water by-pass hose to the No. 2 water by-pass pipe, and slide the clip to secure hose.

HINT:

Attach the clip within the area shown in the illustration.

*a

45°

*b

Left Side of Vehicle

(f) Attach the clamp and connect the HV air conditioning wire.

6. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube sub-assembly to the fuel pump assembly and 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.

7. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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

8. 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

9. INSTALL BATTERY HOLE COVER

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

10. INSTALL REAR NO. 2 FLOOR BOARD

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

11. INSTALL DECK BOARD ASSEMBLY

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

12. INSPECT FOR FUEL LEAK

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

13. PERFORM INITIALIZATION

(a) Perform "Inspection After Repair" after replacing the fuel pump assembly.

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