Complete removal and replacement of all four fuel injectors on the 2019-2024 Toyota RAV4 2.5L I4 engine, including fuel rail removal and system depressurization.

Warnings

Tools required

Parts

• Fuel injector × 4 — 23250-0V030 or 23209-0V030
• Fuel injector O-ring kit × 1 — Use OEM specification
• Fuel rail gasket/seal kit × 1 — Use OEM specification
• Fuel line quick-connect O-rings × 2 — Use OEM specification

Preparation

1. Ensure engine is completely cool to the touch
2. Park vehicle on level ground and engage parking brake
3. Disconnect negative battery terminal and wait 90 seconds for airbag system to discharge
4. Remove engine cover by pulling upward on perimeter clips
5. Clean area around fuel rail and injectors with shop towels to prevent debris entry

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump relay in the engine compartment fuse box (typically labeled EFI MAIN or FUEL PUMP). Remove the relay, then attempt to start the engine. It will run briefly (5-10 seconds) then stall as pressure is depleted. Crank engine 2-3 more times to ensure all pressure is relieved. Turn ignition off and reinstall relay.
   ⚠️Do not skip this step. Fuel system pressure must be fully relieved before disconnecting any fuel lines.
2. 2

   Disconnect fuel supply line
   Locate the fuel supply line connection at the fuel rail (driver side of engine). Place shop towels around connection area. Using appropriate fuel line disconnect tool, press release tabs and pull line straight off rail. Residual fuel will drain; catch with towels and container. Inspect O-rings and replace if damaged.
   ⚠Expect residual fuel spillage even after pressure relief. Immediately wipe up any spills.
3. 3

   Disconnect electrical connectors
   Disconnect the electrical connector from each of the four fuel injectors by pressing the release tab and pulling straight up. Also disconnect any nearby connectors that may interfere with fuel rail removal, including throttle position sensor and IAC valve if present. Move wiring harnesses aside.
4. 4

   Remove vacuum hoses and PCV connections
   Disconnect the vacuum hose from the fuel pressure regulator (if applicable to your specific model year). Remove any PCV hoses or breather hoses attached to the intake manifold near the fuel rail. Label connections if needed for reassembly reference.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
5. 5

   Remove fuel rail mounting bolts
   Locate the two fuel rail mounting bolts (one at each end of the rail). Using a 12mm socket, remove both bolts completely. Keep bolts in a safe location for reinstallation.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
6. 6

   Remove fuel rail assembly
   Carefully pull the fuel rail straight up and away from the intake manifold. The four injectors will remain attached to the rail and pull out of the manifold simultaneously. Use steady, even pressure - do not rock side to side. If injectors are stuck, gently wiggle rail while pulling upward. Once free, place assembly on clean shop towels.
   ⚠Do not pry or use excessive force. Injectors may be seized in place by old O-rings.
7. 7

   Remove injectors from fuel rail
   For each injector: remove the metal retaining clip securing injector to fuel rail using flat blade screwdriver or by hand. Pull injector straight out of fuel rail. Remove and discard old O-rings from each injector (two per injector - upper and lower). Clean injector ports in fuel rail with shop towel.
8. 8

   Inspect and clean injector bores
   Inspect the four injector bores in the intake manifold. Remove any debris, old O-ring material, or carbon buildup using shop towels. Do not allow any debris to fall into intake ports. Verify bores are clean and smooth.
   ⚠Cover intake ports with clean shop towels to prevent debris entry while cleaning.
9. 9

   Prepare new injectors
   Unpack new injectors and verify correct part numbers match OEM specification. Lubricate new O-rings lightly with clean engine oil or provided lubricant. Install upper and lower O-rings on each new injector, ensuring they seat properly in their grooves. Do not over-lubricate.
10. 10

    Install injectors into fuel rail
    Insert each new injector into the fuel rail with a gentle twisting motion until fully seated. Install metal retaining clip on each injector, ensuring clip fully engages and locks injector in place. Verify all four injectors are secure and properly oriented (electrical connectors should face outward).
11. 11

    Install fuel rail assembly
    Apply light coat of clean engine oil to injector O-rings. Align all four injectors with their respective bores in the intake manifold. Press rail down evenly and firmly until all injectors are fully seated. Ensure rail sits flush and level on mounting surfaces.
    ⚠Verify each injector enters its bore squarely. Cocked injectors can damage O-rings or injector tips.
12. 12

    Install fuel rail mounting bolts
    Install both fuel rail mounting bolts hand-tight first to verify proper alignment. Using torque wrench and 12mm socket, tighten bolts to specification in alternating pattern (tighten one side partially, then other side, then final torque both).
    Torque spec

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

    Reconnect all connections
    Reconnect electrical connector to each fuel injector until click is heard or felt. Reconnect vacuum hoses and PCV connections, securing with clamps as needed. Reconnect fuel supply line to fuel rail, pushing firmly until connection clicks and locks. Tug gently to verify secure connection.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
14. 14

    Reconnect battery and prime fuel system
    Reconnect negative battery terminal. Turn ignition to ON position (do not start engine) for 5 seconds, then OFF. Repeat this 3-4 times to prime fuel system and pressurize rails. Inspect all connections for fuel leaks. Wipe area dry and look for fresh wetness.
    ⚠️If any fuel leaks are observed, immediately turn off ignition, relieve pressure, and repair leak before proceeding.
15. 15

    Start engine and verify operation
    Start engine and allow to idle. Engine may run roughly for first 10-20 seconds while system stabilizes. Monitor for fuel leaks around all connections and injector O-rings. Check for smooth idle and absence of misfires. Reinstall engine cover once all verification is complete.

Reassembly

1. Ensure all electrical connectors are fully seated with audible clicks
2. Verify fuel supply line is properly locked onto rail fitting
3. Double-check that no tools or rags were left in engine bay
4. Reinstall engine cover by pressing down on mounting points until clips engage

Verification

• Start engine and verify smooth idle with no misfires or rough running
• Check for fuel odor or visible leaks around fuel rail, injectors, and supply line connection
• Use scan tool to verify no fuel injector-related diagnostic codes are present
• Test drive vehicle and verify normal acceleration and engine performance
• Recheck all connections after first drive and verify no leaks have developed

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