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Home >> Toyota >> 2019 >> RAV4 XLE, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 120 (Fuel System (A25A-FXS) - Service Information (2 Of 2)) >> FUEL PUMP (w/ Canister Pump Module) >> Removal [02/2019 - 08/2020] >> Procedure

Removal [02/2019 - 08/2020]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 
    NOTE:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Refer to PRECAUTION [11/2018 - ]

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [02/2019 - 08/2020]

  3. REMOVE DECK BOARD ASSEMBLY 

    Refer to PROCEDURE - Step 2 [02/2019 - 10/2019] , or refer to PROCEDURE - Step 2 [10/2019 - 08/2020]

  4. REMOVE REAR NO. 2 FLOOR BOARD 

    Refer to PROCEDURE - Step 3 [02/2019 - 10/2019] , or refer to PROCEDURE - Step 3 [10/2019 - 08/2020]

  5. REMOVE BATTERY HOLE COVER 

    Refer to PROCEDURE - Step 4 [02/2019 - 10/2019] , or refer to PROCEDURE - Step 4 [10/2019 - 08/2020]

  6. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [02/2019 - 10/2019] , or refer to INITIALIZATION [10/2019 - 06/2020] , or refer to INITIALIZATION [06/2020 - 08/2020]

  7. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY 

    Refer to PROCEDURE - Step 1

  8. REMOVE REAR SEAT CUSHION LOCK HOOK 

    Refer to PROCEDURE - Step 2

  9. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 8

  10. REMOVE NO. 3 BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 4

  11. REMOVE REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure as for the LH side.

  12. REMOVE NO. 2 BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 6

  13. REMOVE BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 7

  14. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  15. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Fold back the floor carpet.
    2. Remove the 3 bolts and rear floor service hole cover.
      GTY872371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the 3 connectors from the fuel suction with pump and gauge tube assembly and fuel gauge wire.
      GTY848623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FUEL TANK PRESSURE SENSOR 

    Refer to PROCEDURE - Step 3

  17. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Disconnect the fuel tank vent hose sub-assembly from the fuel suction with pump and gauge tube assembly.
      GTY848618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [02/2019 - 08/2020]

  18. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.
      NOTE:
      • Remove any foreign matter on the fuel tube joint before performing this work.
      • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
      • Be sure to disconnect the fuel tube joint by hand.
      • Do not bend, twist, pinch or kink the nylon tube.
      • Cover the disconnected fuel tube joint with a plastic bag to prevent damage and contamination.
      • If the fuel tube joint and plate sub-assembly are stuck, push and pull to release them.
      GTY845899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Tube Joint Clip
      *2 Fuel Tank Main Tube Sub-assembly
      *a Nylon Tube
      *b Fuel Tube Joint
      *c Plate Sub-assembly
      *d O-ring
      Pull off
      Pull off
  19. REMOVE FUEL PUMP GAUGE RETAINER 
    1. Detach the claw and remove the fuel sender gauge wire from the fuel pump gauge retainer.
      GTY848624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the claw and remove the No. 1 fuel tube clamp from the fuel pump gauge retainer.
      GTY848620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the fuel pump gauge retainer.
      1. Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.
        • SST: 09808-01071 
        • SST: 09808-14031 
          1. 09808-01030
          2. 09808-01090

        HINT: 

        Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.

        GTY937945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Plate)
        *b SST (Bolt)
        *c SST (Claw)
        *d Insertion Point
      2. While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).
      3. Install SST (handle) and an extension bar to SST (plate).
        GTY939060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Handle)
        *b Extension Bar
        *c SST (Bolt)
        *d SST (Plate)
        *e SST (Claw)
        • SST: 09808-01071 
        • SST: 09808-14031 
          1. 09808-01010
          2. 09808-01030
          3. 09808-01090
      4. Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing down on SST, rotate SST (handle) slowly to loosen the fuel pump gauge retainer.
        WARNING:

        When turning SST (handle), take care not to hit the console box assembly with your hands or SST (handle).

        NOTE:
        • Do not use any tools other than specified in this operation as this may result in damage to the fuel pump gauge retainer or the fuel tank assembly.
        • Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
        • Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.
        • Do not spin SST too fast or use an impact wrench as this may result in damage to components.
        • If SST comes off of the fuel pump gauge retainer, loosen SST (bolt) and reinstall SST.
      5. While pressing down on the fuel suction with pump and gauge tube assembly, remove the fuel pump gauge retainer.
  20. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Remove the fuel suction with pump and gauge tube assembly from the fuel tank assembly.
      NOTE:

      Be careful not to bend the arm of the fuel sender gauge assembly.

    2. Remove the gasket from the fuel tank assembly.
      GTY872377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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