A25A-FKS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL; 2023 MY RAV4 [10/2022

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM1000000026X1U
Model Year Start: 2023	Model: RAV4	Prod Date Range: [10/2022 - 10/2023]
Title: A25A-FKS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL; 2023 MY RAV4 [10/2022 - 10/2023]

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
*: When performing learning using the Techstream.
Battery terminal is disconnected/reconnected	Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)	Stop and start system
	Perform steering sensor zero point calibration	Lane control system
		Parking support brake system*
		Pre-collision system
	Reset back door close position	Power back door system
	Back door lock initialization	Power door lock control system
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.

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 (-) 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 ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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2. DISCHARGE FUEL SYSTEM PRESSURE

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3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

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

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4. REMOVE INTAKE MANIFOLD

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5. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

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6. 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.

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.

7. 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.

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.

8. 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.