A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL; 2021 MY RAV4 HV [08/2020

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000001R194
Model Year Start: 2021	Model: RAV4 HV	Prod Date Range: [08/2020 - 12/2021]
Title: A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL; 2021 MY RAV4 HV [08/2020 - 12/2021]

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 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
*: When performing learning using the Techstream. Click here
Auxiliary battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane control system
		Parking support brake system*
		Pre-collision system
		Lighting system (EXT) (w/ AFS)
	Memorize steering angle neutral point	Parking assist monitor system
	Memorize steering angle neutral point	Panoramic view monitor system
	Reset back door close position	Power back door system
	Back door lock initialization	Power door lock control system
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.

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.

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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.

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2. DISCHARGE FUEL SYSTEM PRESSURE

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3. REMOVE DECK BOARD ASSEMBLY

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4. REMOVE REAR NO. 2 FLOOR BOARD

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5. REMOVE BATTERY HOLE COVER

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6. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

NOTICE:

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

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7. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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8. REMOVE EGR VALVE ASSEMBLY

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9. REMOVE NO. 2 WATER BY-PASS PIPE

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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.

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11. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

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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.