Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001FHLX
Model Year Start: 2019 Model: RAV4 HV Prod Date Range: [11/2018 - 02/2019]
Title: A25A-FXS (FUEL): FUEL PUMP (for High Pressure): REMOVAL; 2019 MY RAV4 HV [11/2018 - 02/2019]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during fuel pump assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane control system

2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Pre-collision system

Memorize steering angle neutral point

Parking assist monitor system

2019 - 2022 MY RAV4 RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM: INITIALIZATION

Panoramic view monitor system

2019 - 2022 MY RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): INITIALIZATION

Reset back door close position

Power back door system

2019 - 2023 MY RAV4 HV [11/2018 - 10/2023]; DOOR / HATCH: POWER BACK DOOR SYSTEM (for HV Model): INITIALIZATION

Back door lock initialization

Power door lock control system

2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: INITIALIZATION

  • Replacement of fuel pump assembly
  • Replacement of throttle body with motor assembly
  • Cleaning the deposits from the throttle body with motor assembly
  • Replacement of EGR valve assembly
  • Gas leak from exhaust system is repaired

Inspection after repair
  • Poor idle, etc.
  • Engine start function, etc.

2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM (w/o Canister Pump Module): INITIALIZATION

CAUTION:

  • Never perform work on fuel system components near any possible ignition sources.
  • 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.
  • Sparks could cause vaporized fuel to ignite, resulting in a serious accident.
  • 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.

NOTICE:

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

PROCEDURE

1. PRECAUTION

NOTICE:

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.

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

2. DISCHARGE FUEL SYSTEM PRESSURE

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

3. REMOVE DECK BOARD ASSEMBLY

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+

4. REMOVE REAR NO. 2 FLOOR BOARD

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+

5. REMOVE BATTERY HOLE COVER

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+

6. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

NOTICE:

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

Click here 2019 MY RAV4 RAV4 HV [11/2018 - 02/2019]; INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION

7. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (ENGINE CONTROL): THROTTLE BODY: REMOVAL

8. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Remove the fuel pipe clamp from the fuel tube connector.

(b) Disconnect the fuel tube sub-assembly from the fuel pump assembly and fuel delivery pipe sub-assembly.

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

9. REMOVE NO. 2 WATER BY-PASS PIPE

(a) Detach the clamp and disconnect the HV air conditioning wire.

(b) Slide the clip and disconnect the No. 8 water by-pass hose from the No. 2 water by-pass pipe.

(c) Remove the 2 bolts (A) and disconnect the No. 2 water by-pass pipe from the intake manifold.

(d) Remove the bolt (B) and No. 2 water by-pass pipe from the cylinder block sub-assembly.

10. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

CAUTION:

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.

(a) Disconnect the connector from the ignition coil assembly.

(b) Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

Union Nut

Bolt

(c) Remove the bolt.

(d) Loosen the 2 bolts of the fuel pump assembly.

(e) Remove the No. 1 fuel pipe sub-assembly from the fuel delivery pipe and fuel pump assembly.

11. REMOVE FUEL PUMP ASSEMBLY

NOTICE:

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

(a) Disconnect the connector from the fuel pump assembly.

(b) Remove the 2 bolts, fuel pump assembly and fuel pump flange from the cylinder head cover sub-assembly.

(c) Remove the O-ring from the fuel pump assembly.

(d) Remove the fuel pump lifter assembly from the fuel pump lifter guide.

(e) Remove the fuel pump spacer gasket from the cylinder head cover sub-assembly.