LEMON Manuals: Even more car manuals for everyone
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 TANK (w/ Canister Pump Module) >> Removal [10/2023 - ] >> Procedure

Removal [10/2023 - ]: 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 battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.

    Refer to PRECAUTION [11/2018 - ]

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [08/2020 - ]

  3. REMOVE DECK BOARD ASSEMBLY 

    Refer to PROCEDURE - Step 2

  4. REMOVE REAR NO. 2 FLOOR BOARD 

    Refer to PROCEDURE - Step 3

  5. REMOVE BATTERY HOLE COVER 

    Refer to PROCEDURE - Step 4

  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 [10/2023 - ]

  7. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 

    Refer to REMOVAL [10/2023 - ] 

  8. DRAIN FUEL 
  9. REMOVE FRONT FENDER FRONT SPLASH SHIELD LH 

    Refer to PROCEDURE - Step 13

  10. REMOVE FRONT FENDER FRONT SPLASH SHIELD RH 

    Refer to PROCEDURE - Step 14

  11. REMOVE NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 15

  12. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 16

  13. REMOVE FRONT FLOOR COVER LH 
    1. Detach the clip and remove the 2 bolts and 4 screws.
      GTY872389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Loosen the 7 nuts and remove the front floor cover LH from the body.
      GTY872388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FRONT CENTER FLOOR COVER 
    1. Detach the 2 clips and remove the front center floor cover from the body.
      GTY872397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Disconnect the fuel tank vent hose sub-assembly from the fuel tank solenoid main valve assembly.
      GTY848489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [08/2020 - ]

  16. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank main tube sub-assembly from the fuel tube.
      GTY848488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [08/2020 - ]

  17. DISCONNECT FUEL TANK BREATHER TUBE 
    1. Disconnect the fuel tank breather tube from the fuel tank filler pipe assembly.

      Refer to PRECAUTION [08/2020 - ]

      GTY857829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY 
    1. Disconnect the fuel tank filler pipe sub-assembly from the fuel tank filler pipe assembly.
      GTY872399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [08/2020 - ]

  19. DISCONNECT FRONT LOWER NO. 1 FLOOR HEAT INSULATOR 
    1. Detach the clip and disconnect the front lower No. 1 floor heat insulator from the fuel tank band sub-assembly.
      GTY872398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FUEL TANK ASSEMBLY 
    WARNING:

    The fuel tank assembly is very heavy. Be sure to follow the procedure described in the appropriate service information , or the fuel tank assembly may fall off the engine lifter.

    1. Using an engine lifter, support the fuel tank assembly.
      GTY848435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal.

    2. Remove the 4 bolts, fuel tank band and fuel tank band LH.
      GTY872400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Lower the engine lifter and remove the fuel tank assembly.
      NOTE:
      • Be careful not to drop the fuel tank assembly.
      • When removing the fuel tank assembly, tilt it slightly to prevent it from interfering with the surrounding parts.
  21. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Detach the clamp and remove the fuel tank main tube sub-assembly from the fuel tank assembly.
      GTY928494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Disconnect the fuel tank vent hose sub-assembly from the fuel tank evaporation tube sub-assembly.
      GTY848643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [08/2020 - ]

    2. Detach the 2 clamps and remove the fuel tank vent hose sub-assembly from the fuel tank assembly.
      GTY848636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 2 FUEL TANK PROTECTOR 
    1. Detach the 2 claws and remove the No. 2 fuel tank protector from the fuel tank protector sub-assembly.
      GTY914861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Detach the 2 claws and remove the No. 1 fuel tank protector sub-assembly from the fuel tank assembly.
      GTY914860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE NO. 6 FUEL TANK CUSHION 
    1. Remove the 5 No. 6 fuel tank cushions from the fuel tank assembly.
      GTY848490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals