TOYOTA RAV4 2006 Service Repair Manual

2GR-FE FUEL – FUEL SYSTEMFU–9
FU
ON-VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION
(a) Connect the intelligent tester to the DLC3.
(b) Turn the ignition switch ON.
NOTICE:
Do not start the engine.
(c) Select the following tester menus: DIAGNOSIS,
ENHANCED OBD II, ACTIVE TEST and FUEL
PUMP/SPD. Operate the fuel pump.
(d) Touch the fuel hose in the engine compartment to
check the fuel flow, and you will be able to hear the
sound of the fuel pump.
(e) Stop the fuel pump. If there is no fuel flow, the fuel
pump may not be operating. Check the fuel pump
circuit.
2. CHECK FUEL PRESSURE
(a) Check that the battery positive voltage is above 12
V.
(b) Perform the "DISCHARGE FUEL SYSTEM
PRESSURE" procedures (see page FU-1).
(c) Disconnect the cable from the negative (-) battery
terminal.
(d) Disconnect the fuel main tube (see page FU-22).
(e) Install SST (pressure gauge) using SST and a fuel
tube connector as shown in the illustration.
SST 09268-41048 (90467-13001, 95336-08070,
09268-41500), 09268-45014 (09268-41200,
09268-41220, 09268-41250)
(f) Wipe up any gasoline.
(g) Reconnect the cable to the negative (-) battery
terminal.
(h) Start the engine.
(i) Measure the fuel pressure at idle.
Standard fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2,44.1 to 49.7
psi)
• If the fuel pressure is greater than the standard
value, replace the fuel pump.
• If the fuel pressure is less than the standard
value, check the connection of the fuel hose and
the fuel pump.
(j) Stop the engine.
(k) Check that the fuel pressure remains as specified
for 5 minutes after the engine stops.
Standard fuel pressure:
147 kPa (1.5 kgf/cm
2, 21 psi) or more
If the fuel pressure is not as specified, check the fuel
pump or fuel injector.
(l) After checking the fuel pressure, carefully
disconnect the negative (-) battery cable, and
remove SST and fuel tube connector to prevent
gasoline from splashing.
(m) Reconnect the fuel main tube (see page FU-29).
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FU–102GR-FE FUEL – FUEL SYSTEM
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(n) Check for fuel leaks.

2GR-FE FUEL – FUEL INJECTORFU–13
FU
REMOVAL
CAUTION:
Do not allow fuel to spray when removing the pipe
between the high pressure side fuel pump and the fuel
injector. The fuel in the pipe is highly pressurized.
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
• The "DISCHARGE FUEL SYSTEM PRESSURE"
procedures must be performed before
disconnecting any part of the fuel system.
• After performing the "DISCHARGE FUEL SYSTEM
PRESSURE" procedures, pressure will remain in
the fuel line. When disconnecting the fuel line,
place a cloth or equivalent over fittings to reduce
the risk of fuel spray.
(a) Remove the console box (see page IP-16).
(b) Start the engine. After the engine has stopped, turn
the ignition switch OFF.
HINT:
DTC P0171/P0172 (system too lean) may be set.
(c) Check that the engine does not start.
(d) Remove the fuel tank cap, and let the air out of the
fuel tank.
(e) Connect the connector.
(f) Install the console box (see page IP-23).
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
3. REMOVE ENGINE ASSEMBLY
(a) Remove the engine (see page EM-21).
4. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
(See page EM-27)
5. DISCONNECT FUEL MAIN TUBE
(a) Remove the No. 2 fuel pipe clamp.
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FU–142GR-FE FUEL – FUEL INJECTOR
FU
(b) Pinch the tube connector and then pull out the fuel
pipe.
NOTICE:
• Check for foreign matter in the fuel tube
around the fuel tube's connector. Clean it if
necessary. Foreign matter can affect the O-
ring's ability to seal the connector and fuel
main pipe.
• Do not use any tools to separate the
connector and pipe.
• Do not forcefully bend or twist the hose.
• Keep the connector and pipe free from
foreign matter.
• If the connector and pipe are stuck together,
pinch the connector and turn it carefully to
disconnect it.
• Put the connector in a plastic bag to prevent
damage and contamination.
6. REMOVE FUEL INJECTOR ASSEMBLY
(a) Disconnect the 6 injector connectors.
(b) Remove the 5 bolts and fuel delivery pipe together
with the 6 injectors.
NOTICE:
Be careful not to drop the fuel injectors when
removing the fuel delivery pipe.
(c) Remove the 6 insulators from the intake manifold.
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2GR-FE FUEL – FUEL INJECTORFU–15
FU
(d) Pull out the 6 fuel injectors from the fuel delivery
pipe.
(e) Remove the O-ring from each fuel injector.
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FU–162GR-FE FUEL – FUEL INJECTOR
FU
INSPECTION
1. INSPECT FUEL INJECTOR ASSEMBLY
(a) Inspect injector resistance.
(1) Measure the resistance between the terminals.
Standard resistance:
11.6 to 12.4
at 20C (68F)
If the result is not as specified, replace the
injector.
(b) Inspect the injection volume.
CAUTION:
This test involves high-pressure fuel and
electricity. Take every precaution regarding safe
handling of both the fuel and the electricity.
Perform this test in a safe area, and avoid any
sparks or flames. Do not smoke.
(1) Install the fuel tube connector to SST (hose),
then connect the tube connector to the fuel
pipe (vehicle side).
SST 09268-41048 (95336-08070, 09268-
41500)
(2) Install the O-ring to the fuel injector.
(3) Connect SST (adaptor and hose) to the
injector, and hold the injector and union with
SST (clamp).
SST 09268-41048 (09268-41130, 90467-
13001), 09268-41400
(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 volume:
84 to 100 cm
3 (5.1 to 6.0 cu in.) in 15
seconds
Difference between each injector:
16 cm
3 (0.96 cu in.) or less
If the injection volume is not as specified,
replace the injector.
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2GR-FE FUEL – FUEL INJECTORFU–17
FU
(c) Check for leakage.
(1) In the condition above, disconnect the tester
probes of SST (wire) from the battery and
check for fuel leakage from the injector.
Fuel drop:
1 drop or less in 16 minutes
INSTALLATION
1. INSTALL FUEL INJECTOR ASSEMBLY
(a) Apply a light coat of spindle oil or gasoline to 6 new
O-rings, and install an O-ring to each injector.
(b) Apply a light coat of spindle oil or gasoline where
the fuel delivery pipe contacts the O-ring.
(c) Push the fuel injector while twisting it back and forth
to install it in the fuel delivery pipe.
(d) Position the fuel injector connector outward.
NOTICE:
• Be careful not to twist the O-ring.
• After installing the fuel injector, check that it
turns smoothly. If it does not, reinstall it with
a new O-ring.
(e) Install 6 new insulators to the intake manifold.
(f) Place the fuel delivery pipe together with the 6 fuel
injectors into the intake manifold.
NOTICE:
Be careful not to drop the fuel injectors when
installing the fuel delivery pipe.
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FU–182GR-FE FUEL – FUEL INJECTOR
FU
(g) Temporarily install the 5 bolts which are used to hold
the fuel delivery pipe to the intake manifold.
NOTICE:
After installing the fuel injector, check that it
turns smoothly. If it does not, reinstall it with a
new O-ring.
(h) Tighten the 5 bolts which are used to hold the fuel
delivery pipe to the intake manifold.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(i) Connect the 6 fuel injector connectors.
2. CONNECT FUEL MAIN TUBE
(a) Push in the tube connector to the pipe until the tube
connector makes a "click" sound.
NOTICE:
• Check that there is no damage or foreign
objects on the connected part of the fuel pipe.
• After connecting, check if the fuel tube
connector and the pipe are securely
connected by pulling on them.
(b) Install the No. 2 fuel pipe clamp.
3. INSTALL INTAKE AIR SURGE TANK ASSEMBLY (See
page EM-34)
4. INSTALL ENGINE ASSEMBLY
(a) Install the engine (see page EM-31).
5. ADD ENGINE COOLANT (See page CO-8)
6. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
7. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
8. CHECK FOR FUEL LEAKS
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FU–202GR-FE FUEL – FUEL PRESSURE PULSATION DAMPER
FU
INSTALLATION
1. INSTALL FUEL PRESSURE PULSATION DAMPER
(a) Apply a light coat of spindle oil or gasoline to a new
O-ring, and install it to the pulsation damper.
(b) Install the pulsation damper to the fuel delivery pipe.
(c) Install the clip.
2. INSTALL INTAKE AIR SURGE TANK ASSEMBLY (See
page EM-34)
3. INSTALL ENGINE ASSEMBLY
(a) Install the engine (see page EM-31).
4. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL

FU–222GR-FE FUEL – FUEL PUMP
FU
REMOVAL
1. REMOVE FUEL TANK ASSEMBLY
(a) Remove the fuel tank (see page FU-33).
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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