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Home >> Toyota >> 2020 >> RAV4 XLE, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 125 (Fuel System (A25A-FXS) - Inspection) >> Fuel System >> Precaution [11/2018 - 02/2019] >> Precaution [11/2018 - 02/2019]

Precaution [11/2018 - 02/2019]

WARNING: This page is about a different variant/trim than selected.
WARNING:
  • Never perform work on fuel system components near any possible ignition sources.
    Fig 1: Warning: Possible Ignition Sources
    GTY657996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  • Vaporized fuel could ignite, resulting in a serious accident.
  • Do not perform work on fuel system components without first disconnecting the cable from the negative (-) auxiliary battery terminal.
    Fig 2: Warning: Disconnect Cable From Negative Battery Terminal
    GTY657995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  • Sparks could cause vaporized fuel to ignite, resulting in a serious accident.
  • The fuel tank assembly is very heavy. Be sure to follow the procedure described in the service information, or the fuel tank assembly may fall off the engine lifter.
    Fig 3: Fuel Tank Assembly
    GTY563885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  • To prevent serious injury due to fuel spray from the high-pressure fuel lines, always discharge fuel system pressure before removing any fuel system components.
    Fig 4: Discharge Fuel System Before Removing Lines
    GTY613008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. BEFORE WORKING ON FUEL SYSTEM 
    1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) auxiliary battery terminal.
      NOTE:

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

      Refer to PRECAUTION [11/2018 - ]

    2. Do not smoke or work near fire when handling the fuel system.
    3. Keep fuel away from rubber or leather parts.
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    WARNING:
    • Make sure the engine coolant temperature is 60°C (140°F) or less when performing this procedure.
    • Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
    • Pressure will still remain in the fuel lines even after performing the following procedure. When disconnecting a fuel line, cover it with a piece of cloth to prevent fuel from spraying or coming out.
    1. When discharging fuel system pressure by disconnecting the EFI MAIN NO. 2 relay:
      1. Remove the engine room relay block cover.
      2. Remove the EFI MAIN NO. 2 relay.
      3. Remove the front fender front splash shield LH.

        Refer to PROCEDURE - Step 13

      4. Remove the front fender front splash shield RH.

        Refer to PROCEDURE - Step 14

      5. Remove the No. 1 engine under cover.

        Refer to PROCEDURE - Step 15

      6. Remove the No. 2 engine under cover assembly.

        Refer to PROCEDURE - Step 16

      7. Detach the claw and raise the lock lever to disconnect the No. 6 engine wire connector as shown in the illustration.
        GTY926448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Lock Lever
      8. Connect the Techstream to the DLC3.
      9. Turn the power switch on (IG).
      10. Turn the Techstream on.
      11. Put the engine in Inspection Mode (Maintenance Mode).

        Powertrain > Hybrid Control > Utility 

        Tester Display
        Inspection Mode
      12. Start the engine. After the engine has stopped on its own, turn the power switch off.
        NOTE:

        Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

      13. Crank the engine again and make sure that the engine does not start.

        HINT: 

        DTC P0087-00 (Fuel Rail / System Pressure - Too Low), P0171-00 (System Too Lean), P3190-00 (Poor Engine Power), P3191-00 (Engine does not Start) or P3193-00 (Fuel Run Out) may be stored. Clear the DTCs before proceeding to the next step.

      14. Remove the fuel tank cap assembly and discharge the pressure from the fuel tank assembly.
      15. Disconnect the cable from the 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]

      16. Connect the No. 6 engine wire connector and push down the lock lever to attach the claw as shown in the illustration.
        GTY871092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Lock Lever
      17. Install the No. 2 engine under cover assembly.

        Refer to PROCEDURE - Step 65

      18. Install the No. 1 engine under cover.

        Refer to PROCEDURE - Step 66

      19. Install the front fender front splash shield LH.

        Refer to PROCEDURE - Step 67

      20. Install the front fender front splash shield RH.

        Refer to PROCEDURE - Step 68

      21. Install the EFI MAIN NO. 2 relay.
      22. Install the engine room relay block cover.
    2. When discharging fuel system pressure by disconnecting the fuel pump connector:
      1. Remove the bench type rear seat cushion assembly.

        Refer to PROCEDURE - Step 1

      2. Remove the rear seat cushion lock hook.

        Refer to PROCEDURE - Step 2

      3. Remove the rear door scuff plate LH.

        Refer to PROCEDURE - Step 8

      4. Remove the No. 3 battery service cover board.

        Refer to PROCEDURE - Step 4

      5. Remove the rear door scuff plate RH.
      6. Remove the No. 2 battery service cover board.

        Refer to PROCEDURE - Step 6

      7. Remove the battery service cover board.

        Refer to PROCEDURE - Step 7

      8. Remove the 3 bolts and rear floor service hole cover.
      9. Disconnect the connector from the fuel suction with pump and gauge tube assembly.
        GTY857836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      10. Remove the front fender front splash shield LH.

        Refer to PROCEDURE - Step 13

      11. Remove the front fender front splash shield RH

        Refer to PROCEDURE - Step 14

      12. Remove the No. 1 engine under cover.

        Refer to PROCEDURE - Step 15

      13. Remove the No. 2 engine under cover assembly.

        Refer to PROCEDURE - Step 16

      14. Detach the claw and raise the lock lever to disconnect the No. 6 engine wire connector as shown in the illustration.
        Fig 5: Disengage The Claw And Raise The Lock Lever To Disconnect The No. 6 Engine Wire Connector
        GTY770521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Lock Lever
      15. Connect the Techstream to the DLC3.
      16. Turn the power switch on (IG).
      17. Turn the Techstream on.
      18. Put the engine in Inspection Mode (Maintenance Mode).

        Powertrain > Hybrid Control > Utility 

        Tester Display
        Inspection Mode
      19. Start the engine. After the engine has stopped on its own, turn the power switch off.
        NOTE:

        Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

      20. Crank the engine again and make sure that the engine does not start.

        HINT: 

        DTC P0087-00 (Fuel Rail / System Pressure - Too Low), P0171-00 (System Too Lean), P3190-00 (Poor Engine Power), P3191-00 (Engine does not Start) or P3193-00 (Fuel Run Out) may be stored. Clear the DTCs before proceeding to the next step.

      21. Remove the fuel tank cap assembly and discharge the pressure from the fuel tank assembly.
      22. Disconnect the cable from the 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]

      23. Connect the No. 6 engine wire connector and push down the lock lever to attach the claw as shown in the illustration.
        Fig 6: Connect The No. 6 Engine Wire Connector And Push Down The Lock Lever To Engage The Claw
        GTY770081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Lock Lever
      24. Install the No. 2 engine under cover assembly.

        Refer to PROCEDURE - Step 65

      25. Install the No. 1 engine under cover.

        Refer to PROCEDURE - Step 66

      26. Install the front fender front splash shield LH.

        Refer to PROCEDURE - Step 67

      27. Install the front fender front splash shield RH.

        Refer to PROCEDURE - Step 68

      28. Connect the connector to the fuel suction with pump and gauge tube assembly.
      29. Install the rear floor service hole cover with the 3 bolts.

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

        NOTE:

        Securely install the rear floor service hole cover.

      30. Install the battery service cover board.

        Refer to PROCEDURE - Step 5

      31. Install the No. 2 battery service cover board.

        Refer to PROCEDURE - Step 6

      32. Install the rear door scuff plate RH.
      33. Install the No. 3 battery service cover board.

        Refer to PROCEDURE - Step 8

      34. Install the rear door scuff plate LH.

        Refer to PROCEDURE - Step 59

      35. Install the rear seat cushion lock hook.

        Refer to PROCEDURE - Step 13

      36. Install the bench type rear seat cushion assembly.

        Refer to PROCEDURE - Step 14

  3. FUEL LINE 
    1. When disconnecting a high-pressure fuel line, a large amount of fuel will spray. Perform the following procedure:
      1. Discharge fuel system pressure.
      2. Disconnect the fuel tube.
      3. Drain the fuel remaining inside the fuel pump tube into a container.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    2. Quick Type A:

      Perform the following procedure when disconnecting a fuel tube connector.

      NOTE:

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Clamp Type A (No. 1 Fuel Pipe Clamp):
        Fig 7: Disconnect Fuel Tube Connector
        GTY769615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Open
        Pull

        Open the cover of the fuel pipe clamp and remove the fuel pipe clamp from the fuel tube connector.

        2. Fig 8: Open The Cover Of The Fuel Pipe Clamp
        GTY754436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Clamp Type B (Fuel Pipe Clamp):

        Remove the fuel pipe clamp from the fuel tube connector.

      3. Check that there is no foreign matter around the fuel tube connector before disconnecting it. Clean it if necessary.
      4. While holding the retainer at the positions shown in the illustration, pull up the retainer to detach the lock claws.
        Fig 9: Disengage The No. 2 Fuel Pipe Lock Claws
        GTY773963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Retainer Holding Position
        Pull out

        HINT: 

        If the lock claws of the retainer are difficult to detach, detach them using a screwdriver with its tip wrapped with protective tape.

        Fig 10: Removal Of Lock Claws Using Screwdriver With Tip-Wrapped Protective Tape
        GTY745033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Protective Tape
      5. Pull up the retainer while holding it at the positions shown in the illustration and pull off the fuel tube connector.
        Fig 11: Removal Of Fuel Tube Connector With Exploded View
        GTY742438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Nylon Tube
        *e Fuel Pipe
        Retainer Holding Position
        Pull out
        Pull off
      6. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        NOTE:
        • 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).
        • Do not bend, twist, pinch or kink the nylon tube.
      7. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      8. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    3. Quick Type A:

      Perform the following procedure when connecting a fuel tube connector.

      NOTE:

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

      1. Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, and then push in the retainer to secure the connection.
        Fig 12: Fuel Tube Connector
        GTY728620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push in
        NOTE:

        Confirm that the retainer makes a "click" sound when pushed.

        HINT: 

        If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      3. Clamp Type A (No. 1 Fuel Pipe Clamp):

        Install the No. 1 fuel pipe clamp to the fuel tube connector and close the cover of the No. 1 fuel pipe clamp.

      4. Clamp Type B (Fuel Pipe Clamp):

        Install the fuel pipe clamp to the fuel tube connector.

      5. Inspect for fuel leaks.

        See step  1

    4. Quick Type B:

      Perform the following procedure when disconnecting a fuel tube connector.

      NOTE:

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Detach the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.
        Fig 13: Releasing Fuel Line Connector Lock
        GTY638353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        *e Claw
        Push
        Pull out
        Pull off
        NOTE:

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        NOTE:
        • Be sure to disconnect the fuel tube connector by hand.
        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the pipe (fuel pipe).
      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    5. Quick Type B:

      Perform the following procedure when connecting a fuel tube connector.

      NOTE:

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

      1. Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, and then push in the retainer to engage the 2 claws.
        Fig 14: Connecting Fuel Pipe
        GTY662653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Claw
        Push
        Push in
        NOTE:

        Confirm that the retainer makes a "click" sound when pushed.

        HINT: 

        If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      3. Inspect for fuel leaks.

        See step  1

    6. Quick Type C:

      Perform the following procedure when disconnecting a fuel tube connector.

      NOTE:

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Push the claw of the retainer, push the retainer of fuel tube connector, and then pull the fuel tube connector off of the fuel tank assembly.
        Fig 15: Disconnecting The Fuel Tube Connector
        GTY607654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Fuel Tank Assembly
        *e Claw
        Push
        Push
        Pull off
        NOTE:

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel tank assembly are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel tank assembly carefully.
        NOTE:
        • Be sure to disconnect the fuel tube connector by hand.
        • 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 tank assembly).
      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    7. Quick Type C:

      Perform the following procedure when connecting a fuel tube connector.

      NOTE:

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

      1. Pull out the retainer until the retainer makes a "click" sound.
        Fig 16: Pull Out The Retainer
        GTY609639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Pull out
      2. Align the fuel tube connector with the fuel tank assembly, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean gasoline to the tip of the fuel pipe and reinsert it.
        Fig 17: Installing The Fuel Tube Connector
        GTY586773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push
        Push in
      3. Connect the fuel lines and push in the retainer. Check that the fuel tube connector is securely connected by pulling on it.
      4. Inspect for fuel leaks.

        See step  1

    8. Observe the following precautions when handling a nylon tube:
      NOTE:
      • Do not twist the nylon tube of the fuel tube connector or fuel tube connector when connecting it.
      • Do not remove the Ethylene Propylene Diene Monomer (EPDM) rubber protector on the outside of the nylon tube.
      • Do not bend, twist, pinch or kink the nylon tube.
      Fig 18: Observe The Following Precautions
      GTY432431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Tube Connector
      *b Nylon Tube
      *c Ethylene Propylene Diene Monomer (EPDM) Rubber Protector
  4. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 
    NOTE:
    • Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube with pump and gauge assembly. Doing so will cause reassembly of the fuel suction tube with pump and gauge assembly to be impossible as the tube is pressed into the fuel suction plate sub-assembly.
      GTY857835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • When replacing the fuel filter, replace it together with the fuel sub-tank sub-assembly.
  5. INSPECT FOR FUEL LEAK 
    1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs.

      See step  1

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