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Home >> Toyota >> 2025 >> RAV4 Plug-In Hybrid SE >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System (A25A-FXS) - Service Information (PHEV) >> FUEL PUMP (for High Pressure) >> Removal [06/2020 - 12/2021] >> Procedure

Removal [06/2020 - 12/2021]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

    Refer to BEFORE DISCONNECTING BATTERY [06/2020 - 10/2022]

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [06/2020 - ]

  3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to REMOVAL [06/2020 - 12/2021]

  4. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to REMOVAL [06/2020 - ]

  5. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the fuel pipe clamp from the fuel tube connector.
      GTY763614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tube sub-assembly from the fuel pump assembly and fuel delivery pipe sub-assembly.
      GTY763240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [06/2020 - ]

  6. REMOVE NO. 2 WATER BY-PASS PIPE 
    1. Detach the clamp and disconnect the HV air conditioning wire.
      GTY763612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 8 water by-pass hose from the No. 2 water by-pass pipe.
      GTY763613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts (A) and disconnect the No. 2 water by-pass pipe from the intake manifold.
      GTY752505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt (B) and No. 2 water by-pass pipe from the cylinder block sub-assembly.
  7. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY 
    WARNING:

    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.

    1. Disconnect the connector from the ignition coil assembly.
      GTY763619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.
      GTY999487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Union Nut
      Bolt
    3. Remove the bolt.
    4. Loosen the 2 bolts of the fuel pump assembly.
      GTY763239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the No. 1 fuel pipe sub-assembly from the fuel delivery pipe and fuel pump assembly.
  8. REMOVE FUEL PUMP ASSEMBLY 
    NOTE:

    When replacing the fuel pump assembly, it is necessary to replace the No. 1 fuel pipe sub-assembly with a new one.

    1. Disconnect the connector from the fuel pump assembly.
      GTY763237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts, fuel pump assembly and fuel pump flange from the cylinder head cover sub-assembly.
      GTY773537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring from the fuel pump assembly.
      GTY754529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the fuel pump lifter assembly from the fuel pump lifter guide.
      GTY763234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the fuel pump spacer gasket from the cylinder head cover sub-assembly.
      GTY763233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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