A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): INSTALLATION; 2019 MY RAV4 HV [11/2018

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.

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PROCEDURE

1. INSTALL PORT FUEL INJECTOR ASSEMBLY

HINT:

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

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(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}

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

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7. INSTALL FUEL PUMP ASSEMBLY

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8. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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9. CONNECT FUEL TUBE SUB-ASSEMBLY

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

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

10. INSTALL NO. 2 WATER BY-PASS PIPE

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11. INSTALL EGR VALVE ASSEMBLY

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12. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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13. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

NOTICE:

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

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14. INSTALL BATTERY HOLE COVER

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15. INSTALL REAR NO. 2 FLOOR BOARD

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16. INSTALL DECK BOARD ASSEMBLY

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17. INSPECT FOR FUEL LEAK

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18. PERFORM INITIALIZATION

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

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