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Home >> Toyota >> 2020 >> RAV4 XLE, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 121 (Fuel System (A25A-FXS) - Service Information (2 Of 2)) >> FUEL PUMP (w/o Canister Pump Module) >> Installation [11/2018 - 08/2020] >> Procedure

Installation [11/2018 - 08/2020]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Install a new gasket to the fuel tank assembly.
    2. Set the fuel suction with pump and gauge tube assembly to the fuel tank assembly.
      NOTE:
      • Be careful not to bend the arm of the fuel sender gauge assembly.
      • To avoid applying excessive force to the tip of the fuel sender gauge assembly, tilt the fuel sub-tank sub-assembly diagonally and insert it into the fuel tank assembly as shown in the illustration.
      GTY904139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Plate Sub-assembly *2 Fuel Sub-tank Sub-assembly
      *3 Fuel Sender Gauge Assembly - -
    3. Align the protrusions of the fuel suction with pump and gauge tube assembly with the notches in the fuel tank assembly.
      GTY899416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Notch
  2. INSTALL FUEL PUMP GAUGE RETAINER 
    1. Install the fuel pump gauge retainer.
      1. While pressing down on the fuel suction with pump and gauge tube assembly, temporarily install the fuel pump gauge retainer.
      2. Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.
        • SST: 09808-14031 
          1. 09808-01030
          2. 09808-01090
        • SST: 09808-01071 
        GTY937945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Plate)
        *b SST (Bolt)
        *c SST (Claw)
        *d Insertion Point

        HINT: 

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

      3. While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).
      4. Install SST (handle) and an extension bar to SST (plate).
        GTY908905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Handle)
        *b Extension Bar
        *c SST (Plate)
        *d SST (Bolt)
        *e Triangle Mark (Fuel Tank Assembly)
        *f Triangle Mark (Fuel Pump Gauge Retainer)
        • SST: 09808-14031 
          1. 09808-01010
          2. 09808-01030
          3. 09808-01090
        • SST: 09808-01071 
      5. Using SST, rotate the fuel pump gauge retainer so that the triangle mark on the fuel pump gauge retainer is aligned with the triangle mark on the fuel tank assembly to install the fuel suction with pump and gauge tube assembly to the fuel tank assembly.
        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 as this may result in damage to the fuel pump gauge retainer or 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.
        • Make sure that the fuel suction tube set gasket does not come off.
    2. Attach the claw and install the No. 1 fuel tube clamp to the fuel pump gauge retainer.
  3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Push the fuel tube joint of the fuel tank main tube sub-assembly, and install the tube joint clip.
      NOTE:
      • Check that there are no scratches or foreign matter around the connecting parts of the fuel tube joint and plug before performing this work.
      • Check that the fuel tube joint is securely inserted to the end.
      • Check that the tube joint clip is on the collar of the fuel tube joint.
      • After installing the tube joint clip, check that the fuel tank main tube sub-assembly is securely connected by pulling on it.
      GTY860037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Tube Joint Clip
      *a Nylon Tube
      *b Fuel Tube Joint
      *c O-ring
      *d Correct
      *e Incorrect
      GTY872392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. CONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY 
    1. Connect the No. 1 fuel evaporation tube sub-assembly to the fuel suction with pump and gauge tube assembly.

      Refer to PRECAUTION [11/2018 - 02/2019] , or refer to PRECAUTION [02/2019 - 08/2020]

  5. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Connect the 2 connectors to the fuel suction with pump and gauge tube assembly.
    2. Install the rear floor service hole cover with the 3 bolts.

      Torque: 5.4 N.m (55 kgf/cm, 48 in.lbf) 

  6. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  7. INSTALL BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 5

  8. INSTALL NO. 2 BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 6

  9. INSTALL REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure as for the LH side.

  10. INSTALL NO. 3 BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 8

  11. INSTALL REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 59 [11/2018 - 02/2019] , or refer to PROCEDURE - Step 60 [02/2019 - 08/2020]

  12. INSTALL REAR SEAT CUSHION LOCK HOOK 

    Refer to PROCEDURE - Step 13

  13. INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY 

    Refer to PROCEDURE - Step 14

  14. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 
    NOTE:

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

    Refer to INITIALIZATION [11/2018 - 02/2019] , or refer to INITIALIZATION [02/2019 - 10/2019] , or refer to INITIALIZATION [10/2019 - 06/2020] , or refer to INITIALIZATION [06/2020 - 08/2020]

  15. INSTALL BATTERY HOLE COVER 

    Refer to PROCEDURE - Step 3

  16. INSTALL REAR NO. 2 FLOOR BOARD 

    Refer to PROCEDURE - Step 4

  17. INSTALL DECK BOARD ASSEMBLY 

    Refer to PROCEDURE - Step 5

  18. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1 [11/2018 - 02/2019] , or refer to PROCEDURE - Step 1 [02/2019 - ]

  19. PERFORM INITIALIZATION 
    1. Perform "Inspection After Repair" after replacing the fuel pump.

      Refer to INITIALIZATION [11/2018 - 08/2020]

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