Toyota RAV4 2000-05

Fuel Injectors

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Air cleaner assembly
     
    Cylinder head cover
     
    Throttle body from the intake manifold
     
    Distributor
     

  4.  
  5. Remove or disconnect the engine wire from the intake manifold, as follows:

    4 injector connectors
     
    Both engine wire clamps from the intake manifold wire brackets
     
    Engine wire protector from the right side of the intake manifold
     
    Engine wire clamp
     

  6.  
  7. Remove or disconnect the Exhaust Gas Recirculation (EGR) valve, as follows:

    Vacuum hose from portE
     
    EGR hose from the vacuum modulator
     
    Loosen the EGR pipe nut from the cylinder head
     
    Both nuts, EGR valve, pipe assembly and gasket
     

  8.  
  9. Disconnect the engine compartment R/B No. 2
  10.  
  11. Remove or disconnect the fuel inlet hose and delivery pipe, as follows:

    Union bolt, both gaskets and the fuel inlet hose from the fuel filter outlet
     
    Air assist hose from the intake manifold port
     
    Air assist hose
     
    Loosen both delivery pipe-to-cylinder head bolts
     
    Delivery pipe from the 4 injectors
     
    Delivery pipe and fuel inlet hose assembly
     

  12.  
  13. Remove or disconnect the following:

    4 injectors and spacers
     

  14.  


WARNING
Be careful not to drop the injectors and spacers.



O-rings, insulator and grommet from each injector
 

To install:

  1. Install or connect the following:

    New O-rings, insulator and grommet, lubricated with gasoline, to each injector
     
    4 injectors and spacers
     

  2.  
  3. Install or connect the fuel inlet hose and delivery pipe, as follows:

    Delivery pipe and fuel inlet hose assembly
     
    Delivery pipe to the 4 injectors. Tighten both delivery pipe-to-cylinder head bolts to 9 ft. lbs. (13 Nm).
     
    Air assist hose
     
    Air assist hose to the intake manifold port
     
    Union bolt, new gaskets and the fuel inlet hose to the fuel filter outlet. Tighten the union bolt to 22 ft. lbs. (29 Nm).
     

  4.  
  5. Connect the engine compartment R/B No. 2
  6.  
  7. Install or connect the EGR valve, as follows:

    New gasket, pipe assembly and EGR valve. Tighten the nut to 9 ft. lbs. (13 Nm) and the union nut to 43 ft. lbs. (59 Nm).
     
    EGR hose to the vacuum modulator
     
    Vacuum hose from portE
     

  8.  
  9. Install or connect the engine wire to the intake manifold, as follows:

    Engine wire clamp
     
    Engine wire protector to the right side of the intake manifold
     
    Both engine wire clamps to the intake manifold wire brackets
     
    4 injector connectors
     

  10.  
  11. Install or connect the following:

    Distributor
     
    Throttle body to the intake manifold
     
    Cylinder head cover
     
    Air cleaner assembly
     

  12.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Air cleaner assembly
     
    Cylinder head cover
     
    Throttle body from the intake manifold
     
    Distributor
     

  4.  
  5. Remove or disconnect the engine wire from the intake manifold, as follows:

    4 injector connectors
     
    Both engine wire clamps from the intake manifold wire brackets
     
    Engine wire protector from the right side of the intake manifold
     
    Engine wire clamp
     

  6.  
  7. Remove or disconnect the Exhaust Gas Recirculation (EGR) valve, as follows:

    Vacuum hose from port E of the Vacuum Switching Valve (VSV)
     
    EGR hose from the vacuum modulator
     
    Loosen the EGR pipe nut from the cylinder head
     
    Both nuts, EGR valve, pipe assembly and gasket
     

  8.  
  9. Disconnect the engine compartment R/B No. 2
  10.  
  11. Remove or disconnect the fuel inlet hose and delivery pipe, as follows:

    Union bolt, both gaskets and the fuel inlet hose from the fuel filter outlet
     
    Air assist hose from the intake manifold port
     
    Air assist hose
     
    Loosen both delivery pipe-to-cylinder head bolts
     
    Delivery pipe from the 4 injectors
     
    Delivery pipe and fuel inlet hose assembly
     

  12.  
  13. Remove or disconnect the following:
    WARNING
    Be careful not to drop the injectors and spacers.



    4 injectors and spacers
     



    O-rings, insulator and grommet from each injector
     

  14.  

To install:

  1. Install or connect the following:

    New O-rings, insulator and grommet, lubricated with gasoline, to each injector
     
    4 injectors and spacers
     

  2.  
  3. Install or connect the fuel inlet hose and delivery pipe, as follows:

    Delivery pipe and fuel inlet hose assembly
     
    Delivery pipe to the 4 injectors. Tighten both delivery pipe-to-cylinder head bolts to 9 ft. lbs. (13 Nm).
     
    Air assist hose
     
    Air assist hose to the intake manifold port
     
    Union bolt, new gaskets and the fuel inlet hose to the fuel filter outlet. Tighten the union bolt to 22 ft. lbs. (29 Nm).
     

  4.  
  5. Connect the engine compartment R/B No. 2
  6.  
  7. Install or connect the EGR valve, as follows:

    New gasket, pipe assembly and EGR valve. Tighten the nut to 9 ft. lbs. (13 Nm) and the union nut to 43 ft. lbs. (59 Nm).
     
    EGR hose to the vacuum modulator
     
    Vacuum hose from port E of the VSV
     

  8.  
  9. Install or connect the engine wire to the intake manifold, as follows:

    Engine wire clamp
     
    Engine wire protector to the right side of the intake manifold
     
    Both engine wire clamps to the intake manifold wire brackets
     
    4 injector connectors
     

  10.  
  11. Install or connect the following:

    Distributor
     
    Throttle body to the intake manifold
     
    Cylinder head cover
     
    Air cleaner assembly
     

  12.  

2.7L Engines


Click image to see an enlarged view

Fig. Fuel injector arrangement and related components-2.7L engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    WARNING
    The injectors are only retained by their O-rings and will tend to drop out of the fuel rail.



    Throttle body
     
    Fuel injector electrical connectors
     
    Crankshaft Position (CKP) sensor connector
     
    Knock Sensor (KS) connector
     
    Data Link Connector 1 (DLC1) and wire clamp from the brackets
     
    Vacuum line from the fuel pressure regulator
     
    Fuel return hose from the pressure regulator
     
    Union bolt and gaskets
     
    Fuel inlet pipe from the fuel rail
     
    Fuel rail with the injectors attached
     



    4 insulators from the four spacers
     
    Fuel injectors from the fuel rail
     
    O-ring and grommet, discard them
     

  6.  

To install:

  1. Install or connect the following:

    New grommets and O-rings on each injector, lubricated with a light coat of gasoline
     
    Fuel injectors, with the electrical connector facing upwards
     
    New insulators and spacers on the intake manifold
     

  2.  
  3. Temporarily install the bolts holding the delivery pipe to the intake manifold.
  4.  
  5. Check that the injectors rotate smoothly.
  6.  
  7. Install or connect the following:

    Tighten the delivery pipe-to-intake manifold bolts to 15 ft. lbs. (21 Nm).
     
    Injector electrical connectors
     
    Fuel inlet pipe with new gaskets. Tighten the union bolt to 22 ft. lbs. (29 Nm) and the bolt to 14 ft. lbs. (20 Nm).
     
    Fuel return pipe to the fuel pressure regulator
     
    Vacuum line to the pressure regulator
     
    Throttle body
     
    Negative battery cable
     

  8.  

3.4L Engine


Click image to see an enlarged view

Fig. Fuel injector arrangement and related components-3.4L engine



Click image to see an enlarged view

Fig. Install new O-rings and grommets on each injector-3.4L engine

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Depressurize the fuel system.
  4.  
  5. Remove or disconnect the following:

    Air cleaner hose
     
    Upper half of the intake manifold
     
    Fuel pressure regulator
     
    Fuel inlet pipe
     
    Fuel injector electrical connections
     
    Fuel rail with the injectors
     
    Spacers from the intake manifold
     
    Injectors from the delivery pipes
     
    O-rings and grommets, discard them
     

  6.  

To install:

  1. Install or connect the following:

    New grommets and O-rings on each injector, lubricated with a light coat of gasoline
     
    Fuel injector with the electrical connector facing outward
     
    Spacers on the intake manifold
     

  2.  
  3. Temporarily install the bolts to hold the delivery pipes to the intake manifold.
  4.  
  5. Check that the injectors rotate smoothly. If they do not, the O-rings have probably been installed incorrectly.
  6.  
  7. Install or connect the following:

    Fuel injector electrical connectors
     
    Fuel pipe with new gaskets. Tighten the bolts to 25 ft. lbs. (34 Nm) and the delivery pipes-to-intake manifold bolts to 10 ft. lbs. (13 Nm).
     
    Fuel pipe union with new gaskets. Tighten the clamp bolt to 71 inch lbs. (8 Nm).
     
    Fuel pressure regulator
     

  8.  
  9. Inspect the vacuum lines and connections. Look for any loose connections, sharp bends or damage.
  10.  
  11. Install or connect the following:

    Air cleaner
     
    Air cleaner hose
     

  12.  
  13. Start the engine and check for vacuum and fuel leaks.
  14.  

 
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