Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001HH68
Model Year Start: 2019 Model: RAV4 HV Prod Date Range: [02/2019 - 06/2020]
Title: A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL; 2019 - 2020 MY RAV4 HV [02/2019 - 06/2020]

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

Link

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane control system

2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Pre-collision system

Memorize steering angle neutral point

Parking assist monitor system

2019 - 2022 MY RAV4 RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM: INITIALIZATION

Panoramic view monitor system

2019 - 2022 MY RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): INITIALIZATION

Reset back door close position

Power back door system

2019 - 2023 MY RAV4 HV [11/2018 - 10/2023]; DOOR / HATCH: POWER BACK DOOR SYSTEM (for HV Model): INITIALIZATION

Back door lock initialization

Power door lock control system

2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: INITIALIZATION

  • 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.
  • w/ Canister Pump Module:

    2019 MY RAV4 RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM (w/ Canister Pump Module): INITIALIZATION 2020 MY RAV4 RAV4 HV [10/2019 - 08/2020]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM (w/ Canister Pump Module): INITIALIZATION

  • w/o Canister Pump Module:

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

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

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

2. DISCHARGE FUEL SYSTEM PRESSURE

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

3. REMOVE DECK BOARD ASSEMBLY

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+ 2020 MY RAV4 HV [10/2019 - 08/2020]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+

4. REMOVE REAR NO. 2 FLOOR BOARD

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+ 2020 MY RAV4 HV [10/2019 - 08/2020]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+

5. REMOVE BATTERY HOLE COVER

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+ 2020 MY RAV4 HV [10/2019 - 08/2020]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+

6. DISCONNECT CABLE FROM 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 [02/2019 - 10/2019]; INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION 2020 MY RAV4 RAV4 HV [10/2019 - 06/2020]; INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION

7. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (ENGINE CONTROL): THROTTLE BODY: REMOVAL

8. REMOVE EGR VALVE ASSEMBLY

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (EMISSION CONTROL): EGR VALVE: REMOVAL

9. REMOVE NO. 2 WATER BY-PASS PIPE

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (INTAKE / EXHAUST): INTAKE MANIFOLD: REMOVAL+

10. 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.

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

11. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (FUEL): FUEL PUMP (for High Pressure): REMOVAL+

12. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

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

(b) Remove the 2 bolts and fuel delivery pipe sub-assembly 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.

13. REMOVE NO. 1 DELIVERY PIPE SPACER

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

14. REMOVE INJECTOR VIBRATION INSULATOR

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

15. REMOVE NO. 5 ENGINE WIRE

(a) Disconnect the 5 connectors from the 4 port fuel injector assemblies and fuel pressure sensor.

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

16. 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.