TOYOTA RAV4 2006 Service Repair Manual

2AZ-FE FUEL – FUEL INJECTORFU–11
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(c) Remove the 2 bolts, then remove the fuel delivery
pipe together with the 4 fuel injectors.
NOTICE:
Be careful not to drop the fuel injectors when
removing the fuel delivery pipe.
(d) Remove the 2 delivery pipe spacers from the
cylinder head.
(e) Remove the 4 insulators from the cylinder head.
8. REMOVE FUEL INJECTOR ASSEMBLY
(a) Pull the 4 fuel injectors out of the fuel delivery pipe.
INSPECTION
1. INSPECT FUEL INJECTOR ASSEMBLY
(a) Measure the resistance between the injector
terminals.
Standard resistance:
11.6 to 12.4
at 20C (68F)
If the result is not as specified, replace the injector.
(b) Inspect the injector injection.
CAUTION:
Keep the injector away from sparks during the
test.
(1) Connect SST (fuel tube connector) to SST
(hose), then connect them to the fuel pipe
(vehicle side).
SST 09268-31011 (09268-41500, 90467-
13001, 95336-08070)
(2) Install the O-ring to the fuel injector.
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FU–122AZ-FE FUEL – FUEL INJECTOR
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(3) Connect SST (adapter and hose) to the
injector, and hold the injector and union with
SST (clamp).
SST 09268-31011 (09268-41110, 09268-
41130, 09268-41310)
(4) Put the injector into the graduated cylinder.
CAUTION:
Install a suitable vinyl tube onto the injector
to contain gasoline spray.
(5) Operate the fuel pump.
(6) Connect SST (wire) to the injector and the
battery for 15 seconds, and measure the
injection volume with the graduated cylinder.
Test each injector 2 or 3 times.
SST 09842-30080
Standard injection volume:
76 to 92 cm
3 (4.6 to 5.6 cu in.) per 15
seconds
Standard difference between each injector:
16 cm
3 (1.0 cu in.) or less
(c) Inspect the fuel leakage.
(1) Disconnect the SST (wire) tester probes from
the battery and check the fuel leakage from the
injector.
Standard fuel drop:
1 drop or less per 12 minutes
(2) Turn the ignition switch OFF.
(3) Disconnect the cable from the negative (-)
battery terminal.
(4) Remove SST.
SST 09842-30080
(5) Disconnect the intelligent tester from the DLC3.
(6) Reconnect the fuel inlet hose (rear fuel pipe) to
the fuel main tube.
INSTALLATION
1. INSTALL FUEL INJECTOR ASSEMBLY
(a) Apply a light coat of gasoline or spindle oil to new O-
rings, then install one onto each fuel injector.
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2AZ-FE FUEL – FUEL INJECTORFU–13
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(b) Apply a light coat of gasoline or spindle oil to the
part of the fuel delivery pipe which comes into
contact with the O-ring of the fuel injector.
(c) Apply a light coat of gasoline or spindle oil to the O-
ring again, then install the right and left fuel injectors
onto the fuel delivery pipe.
NOTICE:
Make sure that the O-ring is not cracked or
jammed when installing.
(d) Check that the fuel injector rotates smoothly. If the
fuel injector does not rotate, replace the O-ring.
2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
(a) Install 4 new insulators into the cylinder head.
(b) Install the 2 delivery pipe spacers onto the cylinder
head.
(c) Install the fuel delivery pipe together with the 4 fuel
injectors, then temporarily tighten the 2 bolts.
NOTICE:
Be careful not to drop the fuel injectors when
installing the fuel delivery pipe.
(d) Check that the fuel injector rotates smoothly.
If the fuel injector does not rotate, replace the O-
ring.
(e) Tighten the 2 bolts to the specified torque.
Torque: 20 N*m (205 kgf*cm, 15 ft.*lbf)
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FU–142AZ-FE FUEL – FUEL INJECTOR
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(f) Connect the 4 fuel injector connectors.
(g) Install the 2 wire harness clamps.
3. CONNECT NO. 2 VENTILATION HOSE
(a) Connect the ventilation hose to the ventilation valve.
NOTICE:
Make sure that the paint mark and hose clamp
are at the correct angle when installing the hose.
4. CONNECT FUEL MAIN TUBE
(a) Connect the fuel main tube.
(b) Push the fuel tube connector until it makes a "click"
sound.
(c) Install the fuel pipe clamp.
(d) Install the fuel tube to the fuel hose clamp.
5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-413)
6. INSTALL NO. 1 ENGINE COVER (See page ES-414)
7. CONNECT CABLE TO BATTERY NEGATIVE
TERMINAL
8. CHECK FOR FUEL LEAKAGE
(a) Make sure that there are no fuel leaks after
performing maintenance on the fuel system.
(1) Connect the intelligent tester to the DLC3.
(2) Turn the ignition switch ON, and push the
intelligent tester main switch ON.
NOTICE:
Do not start the engine.
(3) Select the Active Test mode on the intelligent
tester.
HINT:
Refer to the intelligent tester operator's manual
for further details.
(4) Check that there are no leaks from the fuel
system.
(5) Turn the ignition switch OFF.
(6) Disconnect the intelligent tester from the DLC3.
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2AZ-FE FUEL – FUEL PRESSURE REGULATORFU–17
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REMOVAL
1. REMOVE FUEL TANK ASSEMBLY
(a) Remove the fuel tank (see page FU-39).
2. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Remove the joint clip and fuel tank main tube.
CAUTION:
• Before removing the tube joint clip, check for
foreign matter around the clip. Clean if
necessary.
• Keep the O-ring free of foreign matter, as it
becomes contaminated easily.
• Do not use any tools in this procedure.
• Do not forcefully bend or twist the tube.
• Put the tube in a plastic bag to prevent
damage and contamination.
• If the fuel suction plate and tube are stuck
together, pinch the tube and turn it carefully
to disconnect it.
• Be careful not to damage the clip. If the clip is
damaged, replace it.
3. REMOVE FUEL TANK VENT TUBE SET PLATE
(a) Remove the 8 bolts and set plate.
4. REMOVE FUEL SUCTION WITH PUMP ASSEMBLY
(a) Disconnect the fuel hose and remove the fuel pump
from the fuel tank.
NOTICE:
Do not damage the fuel pump.
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FU–182AZ-FE FUEL – FUEL PRESSURE REGULATOR
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(b) Remove the gasket from the fuel pump.
5. REMOVE FUEL SUB-TANK ASSEMBLY
(a) Disconnect the wire harness.
(b) Using needle nose pliers, remove the E-ring.
HINT:
Slightly lower the sub-tank to remove the E-ring.
(c) Remove the 2 springs from the 2 shaft.
(d) Detach the 2 claws and remove the sub-tank.
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2AZ-FE FUEL – FUEL PRESSURE REGULATORFU–19
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6. REMOVE BRACKET
(a) Using a screwdriver, detach the 2 claws and remove
the bracket.
HINT:
Tape the screwdriver tip before use.
7. REMOVE FUEL PUMP ASSEMBLY
(a) Detach the 5 claws on the filter and remove the fuel
pump from the fuel filter.
HINT:
When removing the claw, do not disconnect the fuel
main tube.
(b) Disconnect the fuel pump connector.
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(c) Remove the O-ring from the fuel filter.
8. REMOVE FUEL PRESSURE REGULATOR
ASSEMBLY
(a) Remove the fuel pressure regulator from the fuel
filter.
(b) Remove the 2 O-rings.
INSTALLATION
1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
(a) Apply a light coat of gasoline to 2 new O-rings, and
install them onto the fuel pressure regulator.
(b) Install the fuel pressure regulator to the fuel filter.
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2AZ-FE FUEL – FUEL PRESSURE REGULATORFU–21
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2. INSTALL FUEL PUMP ASSEMBLY
(a) Connect the pump harness connector.
(b) Apply gasoline to a new O-ring and instal l the O-ring
to the fuel filter.
(c) Attach the 5 claws to the claw holes and install the
fuel pump.
3. INSTALL BRACKET
(a) Attach the 2 claws to the claw holes and install the
bracket.
4. INSTALL FUEL SUB-TANK ASSEMBLY
(a) Attach the 2 claws to the claw holes and install the
fuel sub-tank.
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FU–222AZ-FE FUEL – FUEL PRESSURE REGULATOR
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(b) Connect the wire harness.
(c) Install the spring to the fuel suction plate shaft and
install it to the sub-tank.
(d) Using needle-nose pliers, install a new E-ring.
HINT:
Slightly lower the sub-tank to install the E-ring.
5. INSTALL FUEL SUCTION WITH PUMP ASSEMBLY
(a) Install a new gasket onto the fuel pump.
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