Toyota RAV4 2000-05

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly discharge the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove or disconnect the following:

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

  8.  
  9. 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
     

  10.  
  11. 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
     

  12.  
  13. Disconnect the engine compartment R/B No. 2
  14.  
  15. 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
     

  16.  
  17. 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
     

  18.  

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:

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

  12.  

 
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