This procedure removes and replaces the high pressure fuel pump located on the cylinder head of the 2.5L I4 engine in 2019-2024 Toyota RAV4 vehicles.

Warnings

Tools required

Parts

• High pressure fuel pump assembly × 1 — 23100-28050 or equivalent OEM
• Fuel pump mounting O-ring × 1 — Use OEM specification
• High pressure fuel line O-rings × 2 — Use OEM specification
• Intake manifold gasket (if damaged) × 1 — Use OEM specification

Preparation

1. Ensure engine is completely cold to the touch
2. Park vehicle on level ground and apply parking brake
3. Disconnect negative battery terminal and wait 90 seconds for airbag system to discharge
4. Position fire extinguisher within immediate reach of work area
5. Remove engine cover by pulling upward on the four corner clips
6. Place absorbent shop towels around the work area to catch fuel spillage

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump relay in the engine compartment fuse box (relay labeled EFI MAIN). Remove the EFI MAIN relay. Attempt to start the engine and let it run until it stalls (usually 3-5 seconds). Attempt to start again to confirm no fuel pressure remains. Turn ignition off and remove key.
   ⚠️This step is critical. Skipping or improperly performing fuel pressure relief can cause fuel to spray under extreme pressure when lines are disconnected.
2. 2

   Verify zero fuel pressure
   Connect a fuel pressure gauge to the fuel rail service port (if equipped) or at a convenient test point. Verify pressure reads 0 PSI. If pressure remains, repeat Step 1. If pressure cannot be relieved, do not proceed.
   ⚠️Do not proceed if any fuel pressure remains in the system.
3. 3

   Remove air intake components
   Disconnect the air intake tube from the throttle body. Loosen the hose clamp at the air filter housing and remove the intake tube assembly. Disconnect the MAF sensor electrical connector. Set components aside to provide access to the fuel system.
   Torque spec

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

   Disconnect fuel rail feed line
   Locate the high pressure fuel line connecting the fuel pump to the fuel rail on the cylinder head. Place shop towels underneath the connection point. Using the appropriate fuel line disconnect tool, carefully disconnect the high pressure line from the fuel rail. Some residual fuel will drain - capture with towels. Remove and discard the old O-ring from the line fitting.
   ⚠Even with pressure relieved, residual fuel will be present. Keep towels ready and work carefully to prevent spillage.
5. 5

   Remove fuel pump electrical connector
   Press the locking tab on the fuel pump electrical connector and carefully pull the connector straight off the pump. Inspect connector terminals for corrosion or damage. If damaged, replacement is required before installation of new pump.
6. 6

   Disconnect low pressure feed line
   Locate the low pressure fuel line entering the high pressure pump from below. Using the fuel line disconnect tool, release the quick-connect fitting and separate the line from the pump. Place towels to catch residual fuel. Inspect the O-ring in the quick-connect fitting - replace if damaged.
7. 7

   Remove pump mounting bolts
   Locate the two mounting bolts securing the high pressure fuel pump to the cylinder head. These are typically 10mm head bolts. Remove both mounting bolts completely and set aside. Keep bolts organized as they will be reused with proper torque.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
8. 8

   Extract fuel pump assembly
   Carefully pull the fuel pump assembly straight out from the cylinder head. The pump has a cam follower that rides on the engine camshaft - withdraw slowly to avoid binding. Once removed, immediately cover the cylinder head opening with a clean shop towel to prevent debris entry. Do not allow anything to fall into the engine.
   ⚠️The cylinder head opening leads directly into the engine timing area. Any debris or objects dropped into this opening can cause catastrophic engine failure. Keep the opening covered at all times.
9. 9

   Inspect and clean mounting surface
   Remove the old O-ring from the pump mounting bore in the cylinder head. Inspect the mounting surface for damage, debris, or scoring. Clean the mounting surface with a non-metallic brush and shop vacuum to remove any dirt or old gasket material. Ensure no debris falls into the engine opening. Inspect the camshaft lobe that drives the pump for wear or damage.
10. 10

    Prepare new fuel pump
    Remove new high pressure fuel pump from packaging. Verify it matches the original pump configuration. Install the new O-ring onto the pump body, ensuring it seats properly in the groove. Lightly lubricate the O-ring with clean engine oil. Do not use petroleum jelly or other lubricants. Verify the cam follower on the new pump moves freely.
11. 11

    Install new fuel pump
    Position the fuel pump cam follower to align with the camshaft lobe (rotate engine by hand if necessary for alignment). Carefully insert the pump assembly straight into the cylinder head bore, ensuring the O-ring does not roll or become damaged. Push pump fully into place until it seats against the cylinder head mounting surface. The pump should sit flush with no gaps.
    ⚠Do not force the pump. If resistance is felt, remove and check for proper cam follower alignment and O-ring positioning.
12. 12

    Install mounting bolts
    Install both mounting bolts finger-tight to hold the pump in position. Using a torque wrench, tighten the mounting bolts in a cross pattern to the specified torque of 27 Nm (20 lb-ft). Verify pump is seated evenly against the cylinder head with no gaps around the O-ring seal.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
13. 13

    Reconnect low pressure fuel line
    Install a new O-ring on the low pressure fuel line quick-connect fitting if replacing. Push the fuel line firmly onto the pump inlet port until the quick-connect fitting clicks into place. Tug gently on the line to verify it is securely locked.
14. 14

    Reconnect high pressure fuel line
    Install a new O-ring onto the high pressure fuel line fitting. Align the high pressure line to the fuel rail connection point. Thread the fitting by hand to ensure proper alignment, then tighten to the specified torque of 27 Nm (20 lb-ft) using a torque wrench. Do not over-tighten as this can damage the fitting or O-ring.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
15. 15

    Reconnect electrical connector
    Push the electrical connector onto the fuel pump until it clicks into place. Verify the locking tab is fully engaged. Gently pull on the connector to confirm it is secure.

Reassembly

1. Reinstall air intake components, ensuring the MAF sensor connector is securely attached
2. Tighten intake tube hose clamps to 3.0 Nm (2.0 lb-ft)
3. Reinstall the EFI MAIN relay in the fuse box
4. Reconnect the negative battery terminal
5. Reinstall engine cover by pressing down on mounting clips until they snap into place
6. Remove all shop towels and tools from engine bay

Verification

• Turn ignition to ON position (do not start engine) and listen for fuel pump priming for 2-3 seconds. Repeat this 3-4 times to pressurize the fuel system
• Inspect all fuel line connections for any signs of fuel leakage while system is pressurized
• Start the engine and allow it to idle. Monitor for smooth operation and check for fuel leaks at all connection points
• With engine running, carefully inspect the high pressure fuel pump mounting area and all fuel line connections for any seepage or leaks
• If any fuel leaks are detected, immediately shut off engine, relieve fuel pressure, and correct the issue before operating vehicle
• Road test vehicle under normal driving conditions and verify proper engine performance with no hesitation or fuel delivery issues
• After road test, perform a final visual inspection of all fuel connections with engine off

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