Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001HH69
Model Year Start: 2019 Model: RAV4 HV Prod Date Range: [02/2019 - 08/2020]
Title: A25A-FXS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL; 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]

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 direct 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 direct 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 2020 MY RAV4 RAV4 HV [06/2020 - 08/2020]; INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION

7. REMOVE INTAKE MANIFOLD

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

8. 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+

9. REMOVE FUEL DELIVERY PIPE

NOTICE:

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

(a) Detach the clamp and disconnect the connector from the fuel pressure sensor.

(b) Disconnect the 4 connectors from the 4 direct fuel injector assemblies.

NOTICE:

Make sure to disconnect the connectors carefully.

(c) Remove the 4 bolts and fuel delivery pipe from the cylinder head sub-assembly.

NOTICE:

  • Make sure not to touch or strike the tips of the direct fuel injector assemblies.
  • Pull and remove the fuel delivery pipe in a straight line without tilting it.

10. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

(a) Secure the fuel delivery pipe in a vise between aluminum plates and pull out the 4 direct fuel injector assemblies.

NOTICE:

  • Pull and remove each direct fuel injector assembly in a straight line to avoid damaging the seal surface of the fuel delivery pipe O-ring.
  • After removing the direct fuel injector assemblies, remove any O-rings, No. 1 fuel injector back-up rings and No. 3 fuel injector back-up rings remaining on the fuel delivery pipe side.
  • Attach a tag or label with the corresponding cylinder number to each direct fuel injector assembly so that they can be installed to their original locations.
  • Cover the tip of each direct fuel injector assembly to prevent it from being damaged.

(b) Remove the nozzle holder clamp from each direct fuel injector assembly.

(c) Using needle nose pliers, remove the No. 3 fuel injector back-up ring from each direct fuel injector assembly.

NOTICE:

Do not damage the area that contacts the O-ring.

(d) Remove the O-ring and No. 1 fuel injector back-up ring from each direct fuel injector assembly.

(e) Remove the C-ring and injector vibration insulator from each direct fuel injector assembly.

11. REMOVE FUEL INJECTOR SEAL

(a) Using the tip of needle nose pliers, pinch and pull the fuel injector seal at several points to stretch it.

NOTICE:

  • Excessively pinching the fuel injector seal may damage the groove of the direct fuel injector assembly.
  • If a direct fuel injector assembly is dropped or the tip of the direct fuel injector assembly is struck, replace it with a new one.

(b) Remove the fuel injector seal from each direct fuel injector assembly.