Replacing Fuel Injectors In A Rav4: A Step-By-Step Guide

Replacing a fuel injector in a Toyota RAV4 typically costs between $580 and $640, with parts ranging from $408 to $422 and labor between $172 and $218. The process involves relieving the pressure within the fuel rail, removing the upper plenum on the intake manifold, disconnecting the electrical connectors, and installing a new injector with a new O-ring. It is important to note that this is not a DIY job and should be left to a professional due to the risk of fire and the complexity of the repair.

Discharge the fuel system pressure

To discharge the fuel system pressure on a RAV4, you must first relieve the pressure within the fuel rail. This can be done by briefly running the engine with the fuel pump fuse removed. Here are the steps to discharge the fuel system pressure:

Step 1: Remove the fuel pump fuse

Turn off the engine and locate the fuel pump fuse in the engine bay. Remove the fuse by pulling it out of the fuse box.

Step 2: Briefly run the engine

With the fuel pump fuse removed, briefly turn on the ignition and start the engine. The engine will not start, but this action will release any residual pressure in the fuel rail.

Step 3: Wait for the engine to stop

Turn off the ignition and wait for the engine to come to a complete stop.

Step 4: Replace the fuel pump fuse

Once the engine has stopped, turn off the ignition and replace the fuel pump fuse. Ensure that it is securely inserted into the fuse box.

Step 5: Check for fuel leaks

Before proceeding, it is important to check for any fuel leaks in the system. Make sure there are no external leaks, and no fuel odour can be detected.

Step 6: Disconnect the battery

Disconnect the cable from the negative (-) battery terminal. Wait at least 90 seconds after disconnecting the cable to prevent airbag and seat belt pretensioner activation.

Step 7: Discharge the fuel system

Now, you can discharge the fuel system pressure. Refer to the RAV4 service manual for the specific procedure, as it may vary slightly depending on the model year of your RAV4. The procedure typically involves removing the console box, disconnecting and reconnecting the connector, and releasing air from the fuel tank.

Remember to exercise extreme caution when working with fuel. Always disconnect the battery and take the necessary precautions to prevent fires. It is recommended to have a qualified professional perform fuel injector-related repairs.

Remove the fuel delivery pipe sub-assembly

Firstly, it is important to note that the battery should always be disconnected when working with fuel. Wait at least 90 seconds after disconnecting the cable from the negative terminal to prevent airbag and seat belt pretensioner activation.

Now, to begin removing the fuel delivery pipe sub-assembly:

Step 1: Remove the two wire harness clamps.

Step 2: Disconnect the four fuel injector connectors.

Step 3: Remove the two bolts, then carefully remove the fuel delivery pipe along with the four fuel injectors. Be cautious not to drop the fuel injectors during this step.

Step 4: Remove the two delivery pipe spacers from the cylinder head.

Step 5: Remove the four insulators from the cylinder head.

At this point, the fuel delivery pipe sub-assembly should be successfully removed from the vehicle. It is important to note that working on fuel systems can be dangerous, and it is recommended to have a professional perform this task.

Additionally, here are some extra precautions and tips to consider:

• Ensure you are in a well-ventilated area and take the necessary fire safety precautions.
• Wear the appropriate safety gear, including gloves and eye protection.
• Have a fire extinguisher nearby in case of any accidents.
• Do not forcibly bend or twist the fuel lines.
• Cover the disconnected parts with a plastic bag or cloth to protect them and reduce the risk of fuel spray.
• Refer to the vehicle's service manual for additional instructions and diagrams specific to your model.

By following these steps and taking the necessary precautions, you can safely remove the fuel delivery pipe sub-assembly from your Toyota RAV4.

Remove the fuel injector assembly

To remove the fuel injector assembly, you will need to first relieve the pressure within the fuel rail. This can be done by briefly running the engine with the fuel pump fuse removed.

Next, remove the upper plenum on the intake manifold, along with any cables, hoses, or wiring that may restrict access to the fuel rail. Disconnect the supply and return lines from the fuel rail, and then unlock and remove the electrical connectors from each fuel injector. The fuel rail can then be unbolted and removed from the intake manifold.

Now, carefully remove the fuel injectors from the fuel rail, taking care not to let any debris enter the exposed openings. The fuel injectors are usually held in place by an O-ring seal within a finely polished bore in the fuel rail. Once removed, the fuel injectors can be serviced or replaced.

Inspect the fuel injector assembly

To inspect the fuel injector assembly of a RAV4, you will first need to remove the fuel injector assembly. To do this, perform the following steps:

• Remove the console box.
• Disconnect the connector.
• Start the engine. After the engine has stopped, turn the ignition switch off.
• Remove the fuel tank cap, and let the air out of the fuel tank.
• Connect the connector.
• Install the console box.
• Disconnect the cable from the negative battery terminal.
• Remove the engine cover.
• Remove the air cleaner cap sub-assembly.
• Disconnect the fuel main tube.
• Remove the fuel tube from the fuel hose clamp.
• Remove the fuel pipe clamp.
• Wipe off any dirt on the fuel tube connector.
• Hold the fuel tube connector, then install the SST.
• Turn the SST to align the retainer inside the fuel tube connector with the chamfered part of the SST.
• Insert the SST into the fuel tube and hold it. Then, push the fuel tube connector toward the SST side.
• Mount the retainer of the fuel tube connector onto the chamfered part of the SST.
• Slide the SST and fuel tube connector together towards the fuel tube until they make a "click" sound, and then disconnect the fuel tube.
• Drain the fuel remaining inside the fuel tube.
• Cover the fuel tube and fuel pipe with a plastic bag to protect the disconnected parts.
• Disconnect the ventilation hose from the ventilation valve.
• Remove the fuel delivery pipe sub-assembly.
• Remove the wire harness clamps.
• Disconnect the fuel injector connectors.
• Remove the bolts, then remove the fuel delivery pipe together with the fuel injectors.
• Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
• Remove the delivery pipe spacers from the cylinder head.
• Remove the insulators from the cylinder head.
• Pull the fuel injectors out of the fuel delivery pipe.

Now that the fuel injector assembly has been removed, you can begin the inspection process:

First, measure the resistance between the injector terminals. The standard resistance should be between 11.6 and 12.4 ohms at 20°C (68°F). If the result is not within this range, the injector should be replaced.

Next, inspect the injector injection. Keep the injector away from sparks during the test. Connect the SST (fuel tube connector) to the SST (hose), then connect them to the fuel pipe (vehicle side). Put the injector into the graduated cylinder and install a suitable vinyl tube onto the injector to contain gasoline spray. Operate the fuel pump and connect the SST (wire) to the injector and the battery for 15 seconds. Measure the injection volume with the graduated cylinder and test each injector 2 or 3 times. The standard injection volume should be between 76 and 92 cm3 per 15 seconds, with a standard difference of 16 cm3 or less between each injector.

Finally, inspect the fuel injector for leaks. Disconnect the SST (wire) tester probes from the battery and check for fuel leakage from the injector. The standard should be 1 drop or less per 12 minutes.

Install the fuel injector assembly

To install the fuel injector assembly, start by applying a light coat of gasoline or spindle oil to the new O-rings. Then, install one O-ring onto each fuel injector. Next, apply a light coat of gasoline or spindle oil to the part of the fuel delivery pipe that comes into contact with the O-ring of the fuel injector. After that, install the right and left fuel injectors onto the fuel delivery pipe, ensuring that the O-ring is not cracked or jammed. Check that the fuel injector rotates smoothly; if it does not, replace the O-ring.

Now, install four new insulators into the cylinder head, followed by the two delivery pipe spacers. Then, install the fuel delivery pipe together with the four fuel injectors, temporarily tightening the two bolts. Again, be careful not to drop the fuel injectors when installing the fuel delivery pipe. Check once more that the fuel injector rotates smoothly; if it does not, replace the O-ring. Now, tighten the two bolts to the specified torque: 20 N*m (205 kgf*cm, 15 ft.*lb).

Connect the four fuel injector connectors and install the two wire harness clamps. Finally, connect the number two ventilation hose to the ventilation valve, ensuring that the paint mark and hose clamp are at the correct angle when installing the hose.

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