This procedure covers the removal and replacement of a single fuel injector on the 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine, including relieving fuel system pressure and accessing the fuel rail.

Warnings

Tools required

Parts

• Fuel injector × 1 — Use OEM specification (23250-0V050 or equivalent)
• Fuel injector O-ring kit × 1 — Use OEM specification
• Fuel line O-rings × 1 — Use OEM specification

Preparation

1. Ensure engine is completely cool to the touch
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery terminal and wait 90 seconds for airbag system to discharge
4. Place shop towels around work area to absorb spilled fuel
5. Have container ready to catch residual fuel from lines and rail

Procedure

1. 1

   Relieve fuel system pressure
   Remove the fuel pump relay (EFI fuse) from the engine compartment fuse box. Attempt to start the engine and let it run until it stalls from fuel starvation. Crank the engine for an additional 3-5 seconds to ensure pressure is fully relieved. Turn ignition off and reinstall the fuel pump relay.
2. 2

   Remove engine cover
   Grasp the plastic engine cover at the front corners and pull upward firmly to release the mounting grommets. Lift the cover away from the engine bay. There are no fasteners on this cover; it is retained by rubber grommets only.
3. 3

   Disconnect air intake tube
   Loosen the hose clamp at the throttle body using a flat blade screwdriver or 7mm socket. Disconnect the mass airflow sensor electrical connector by pressing the tab and pulling straight out. Remove the entire air intake tube from the throttle body to air filter housing to gain access to the fuel rail.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
4. 4

   Disconnect fuel supply line
   Locate the fuel supply line on the driver's side of the fuel rail. Place shop towels beneath the connection point. Press the tabs on the quick-disconnect fitting and pull the fuel line straight off the rail. Some residual fuel will drain; capture it with towels. Inspect the line fitting for damage.
5. 5

   Disconnect fuel injector electrical connectors
   Press down on the locking tab of each fuel injector connector and pull straight up to disconnect. You may need to disconnect all four injectors to provide clearance for fuel rail removal. Note the routing of the injector wiring harness for reassembly.
6. 6

   Remove fuel rail mounting bolts
   Locate the two fuel rail mounting bolts, one at each end of the fuel rail. Use a 12mm socket to remove both bolts completely. Keep these bolts organized as they will be reused during installation.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
7. 7

   Remove fuel rail assembly
   Carefully pull the fuel rail straight upward with even pressure on both ends. The injectors will pull out of the intake manifold with the rail. Rock the rail gently side-to-side if it resists removal, but do not pry against the rail itself. Once free, move the fuel rail assembly to a clean work surface.
8. 8

   Remove failed fuel injector
   Identify the injector to be replaced. Use needle nose pliers to remove the metal retaining clip that secures the injector to the fuel rail. Pull the clip straight out of its groove. Once the clip is removed, pull the injector straight out of the fuel rail with a slight twisting motion if needed.
9. 9

   Remove and inspect old O-rings
   Remove both O-rings from the old injector (one upper near the fuel rail connection, one lower that seals to the manifold). Inspect the fuel rail bore and intake manifold port for any debris, damage, or old O-ring material. Clean thoroughly with a lint-free cloth. Do not allow debris to enter the fuel rail or manifold openings.
10. 10

    Install new O-rings on replacement injector
    Lubricate the new O-rings with clean gasoline or light engine oil. Install both new O-rings onto the replacement injector in their correct positions. Ensure O-rings are seated properly in their grooves and are not twisted or pinched. The upper O-ring seals to the fuel rail, the lower seals to the intake manifold.
11. 11

    Install replacement injector to fuel rail
    Insert the new injector into the fuel rail bore with a slight twisting motion to avoid damaging the O-ring. Push the injector in until it is fully seated. Install the metal retaining clip into its groove to secure the injector to the rail. Ensure the clip is fully engaged on both sides.
12. 12

    Reinstall fuel rail assembly
    Lubricate all lower injector O-rings with clean gasoline. Align all four injectors with their respective ports in the intake manifold. Press the fuel rail downward evenly on both ends until all injectors are fully seated in the manifold. Install both fuel rail mounting bolts and tighten to specification in a crisscross pattern.
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)
13. 13

    Reconnect fuel supply line
    Install a new O-ring on the fuel supply line quick-disconnect fitting if provided in your O-ring kit. Push the fuel line straight onto the fuel rail connection until you hear and feel a distinct click. Tug on the line to verify it is locked in place.
14. 14

    Reconnect electrical connections and air intake
    Reconnect all fuel injector electrical connectors, ensuring each clicks into place securely. Reinstall the air intake tube to the throttle body and tighten the hose clamp to specification. Reconnect the mass airflow sensor electrical connector.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
15. 15

    Prime fuel system and check for leaks
    Reconnect the negative battery terminal. Turn the ignition to ON position (without starting) for 2 seconds, then OFF. Repeat this cycle 3-4 times to prime the fuel system. Inspect all fuel connections for leaks. Start the engine and immediately check for fuel leaks around the replaced injector and fuel line connections. Allow engine to idle for 2 minutes while monitoring for leaks.

Reassembly

1. Reinstall engine cover by aligning grommets and pressing down firmly until seated
2. Clear any diagnostic trouble codes that may have been set during the repair procedure
3. Ensure no tools or shop towels were left in the engine bay

Verification

• Start engine and verify smooth idle with no misfires or rough running
• Check for fuel odor or visible leaks around all disturbed fuel connections
• Use a scan tool to verify no active misfire codes are present for the replaced injector cylinder
• Test drive vehicle and confirm normal acceleration and engine performance
• Recheck fuel connections after test drive for any delayed leaks

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