This procedure covers the removal and replacement of the fuel rail assembly on the 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine, including fuel pressure relief and injector handling.

Warnings

Tools required

Parts

• Fuel rail assembly × 1 — Use OEM specification
• Fuel injector O-rings (if not included with rail) × 4 — 23209-0P010 or equivalent
• Fuel line O-rings × 2 — Use OEM specification
• Fuel injector insulators/grommets × 4 — 23291-21010 or equivalent

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely if recently operated
3. Disconnect negative battery terminal and wait 90 seconds for airbag system to discharge
4. Remove engine cover by pulling upward on the four corner clips
5. Have shop towels and catch pan ready to contain fuel spillage

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump relay in the engine compartment fuse box (relay EFI1). Remove the relay, then attempt to start the engine. The engine will start briefly then stall as fuel pressure is depleted. Crank the engine 2-3 more times to ensure all pressure is relieved. Turn ignition off and reinstall the relay.
   ⚠️Ensure ignition is off before proceeding to disconnect fuel lines.
2. 2

   Disconnect air intake system
   Loosen the hose clamp at the throttle body using a flathead screwdriver or socket. Disconnect the mass airflow sensor electrical connector. Remove the air intake tube by releasing it from the throttle body and air filter housing. Set aside the intake assembly.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
3. 3

   Disconnect fuel feed line
   Locate the fuel feed line connection at the fuel rail inlet (driver side of engine). Place shop towels around the connection. Using the appropriate fuel line disconnect tool, depress the retaining tabs and pull the fuel line straight off the rail. Some residual fuel will drain; catch it with towels and pan. Inspect the O-rings on the line and replace if damaged.
   ⚠Do not pry or twist the fuel line fitting as this can damage the quick-connect mechanism.
4. 4

   Disconnect fuel injector electrical connectors
   Locate all four fuel injector electrical connectors on top of the fuel rail. Press down on the locking tab of each connector while pulling upward to disconnect. Note the routing of the injector wiring harness for reinstallation.
5. 5

   Remove vacuum hose and bracket
   Disconnect the vacuum hose from the fuel pressure regulator if equipped with external regulator (some models have internal regulator). Remove any wiring harness brackets or clips attached to the fuel rail using a 10mm socket. Keep track of all bracket bolts.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
6. 6

   Remove fuel rail mounting bolts
   Locate the two fuel rail mounting bolts (one on each end of the rail). Using a 12mm socket, remove both bolts completely. Keep the bolts in a safe location as they will be reused unless damaged.
   Torque spec

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

   Remove fuel rail assembly
   Carefully pull the fuel rail straight upward, applying even pressure on both ends. The injectors will pull out of the intake manifold with the rail. Use a gentle rocking motion if needed, but do not pry. Once free, place the fuel rail assembly on a clean work surface. Cover the open injector ports in the intake manifold with clean shop towels to prevent debris entry.
   ⚠Do not allow dirt or debris to enter the intake manifold ports. Foreign material can cause severe engine damage.
8. 8

   Remove injectors from old rail (if reusing injectors)
   If reusing the injectors with a new rail, remove the injector retaining clips from each injector on the old rail. Pull each injector straight out of the rail. Remove and discard all old O-rings and insulators from each injector. Clean the injector bodies with a lint-free cloth. Do not use carburetor cleaner on injector electrical connectors.
   ℹ️This step only applies if transferring injectors to a new rail. If installing a complete rail assembly, skip to step 10.
9. 9

   Install new O-rings and prepare injectors
   Lubricate new O-rings lightly with clean gasoline or O-ring lubricant. Install new upper and lower O-rings on each injector, ensuring they are seated in their grooves. Install new injector insulators/grommets. Install injectors into the new fuel rail and secure with retaining clips, ensuring clips are fully seated.
10. 10

    Prepare intake manifold ports
    Remove the shop towels from the intake manifold injector ports. Inspect each port for debris or damage. If old injector insulators remained in the manifold, carefully remove them with needle nose pliers. Install new insulators into the manifold ports if required.
11. 11

    Install fuel rail assembly
    Lubricate the injector O-rings lightly with clean gasoline. Align all four injectors with their respective ports in the intake manifold. Press the rail down evenly and firmly until all injectors are fully seated in the manifold. Ensure the rail mounting bolt holes align with the manifold.
12. 12

    Install fuel rail mounting bolts
    Install both fuel rail mounting bolts finger-tight first to ensure proper alignment. Using a torque wrench and 12mm socket, tighten both bolts to specification in a cross pattern (alternate between bolts).
    Torque spec

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

    Reconnect electrical and vacuum connections
    Reconnect all four fuel injector electrical connectors, ensuring each clicks into place securely. Reinstall any wiring harness brackets removed earlier and torque bracket bolts to specification. Reconnect the vacuum hose to the fuel pressure regulator if applicable.
    Torque spec

    Bracket Bolts20 Nm (15 lb-ft)
14. 14

    Reconnect fuel feed line
    Install new O-rings on the fuel feed line if not already replaced. Push the fuel line straight onto the fuel rail inlet until you hear and feel a distinct click indicating the quick-connect is locked. Gently pull on the line to verify it is secure.
15. 15

    Reinstall air intake system
    Reinstall the air intake tube to the throttle body and air filter housing. Reconnect the mass airflow sensor electrical connector. Tighten the throttle body hose clamp to specification.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)

Reassembly

1. Reconnect the negative battery terminal
2. Reinstall the engine cover by pressing down on the four corner clips until they lock
3. Turn the ignition to ON position (do not start) for 2 seconds, then OFF. Repeat this 3 times to prime the fuel system
4. Check all connections for fuel leaks before starting the engine

Verification

• Start the engine and inspect all fuel connections for leaks, particularly at the fuel feed line and around each injector
• Allow engine to idle for 2-3 minutes while monitoring for fuel odor or visible leaks
• Check for proper engine idle quality and smooth acceleration with no hesitation
• Verify no check engine light or fuel system-related diagnostic trouble codes are present
• Re-inspect all connections after the engine reaches operating temperature and cools down

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