| Last Modified: 05-08-2025 | 6.11:8.1.0 | Doc ID: RM100000001HH2Z |
| Model Year Start: 2019 | Model: RAV4 HV | Prod Date Range: [02/2019 - ] |
| Title: A25A-FXS (FUEL): FUEL PUMP (w/ Canister Pump Module): INSTALLATION; 2019 - 2025 MY RAV4 HV [02/2019 - ] | ||
INSTALLATION
PROCEDURE
1. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
(a) Install a new gasket to the fuel tank assembly.
(b) Set the fuel suction with pump and gauge tube assembly to the fuel tank assembly.
NOTICE:
- 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.
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*1 |
Plate Sub-assembly |
*2 |
Fuel Sub-tank Sub-assembly |
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*3 |
Fuel Sender Gauge Assembly |
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(c) Align the protrusions of the fuel suction with pump and gauge tube assembly with the notches in the fuel tank assembly. |
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2. INSTALL FUEL PUMP GAUGE RETAINER
(a) 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.
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(2) Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer. SST: 09808-14031 09808-01030 09808-01090 SST: 09808-01071 HINT: Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer. |
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(3) While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).
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(4) Install SST (handle) and an extension bar to SST (plate). SST: 09808-14031 09808-01010 09808-01030 09808-01090 SST: 09808-01071 |
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(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.
CAUTION:
When turning SST (handle), take care not to hit the console box assembly with your hands or SST (handle).
NOTICE:
- 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.
(b) Attach the claw and install the No. 1 fuel tube clamp to the fuel pump gauge retainer.
(c) Attach the claw and install the fuel sender gauge wire to the fuel pump gauge retainer.
3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Push the fuel tube joint of the fuel tank main tube sub-assembly, and install the tube joint clip.
NOTICE:
- 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.
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*1 |
Tube Joint Clip |
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*a |
Nylon Tube |
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*b |
Fuel Tube Joint |
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*c |
O-ring |
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*d |
Correct |
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*e |
Incorrect |
4. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY
(a) Connect the fuel tank vent hose sub-assembly to the fuel suction with pump and gauge tube assembly.
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![2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION](/t3Portal/stylegraphics/info.gif)
5. INSTALL FUEL TANK PRESSURE SENSOR
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6. INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Connect the 3 connectors to the fuel suction with pump and gauge tube assembly and fuel gauge wire.
(b) Install the rear floor service hole cover with the 3 bolts.
Torque:
5.4 N·m {55 kgf·cm, 48 in·lbf}
(c) Return the floor carpet to its original position.
7. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY
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8. INSTALL BATTERY SERVICE COVER BOARD
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9. INSTALL NO. 2 BATTERY SERVICE COVER BOARD
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10. INSTALL REAR DOOR SCUFF PLATE RH
HINT:
Use the same procedure as for the LH side.
11. INSTALL NO. 3 BATTERY SERVICE COVER BOARD
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12. INSTALL REAR DOOR SCUFF PLATE LH
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13. INSTALL REAR SEAT CUSHION LOCK HOOK
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14. INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY
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15. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
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16. INSTALL BATTERY HOLE COVER
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17. INSTALL REAR NO. 2 FLOOR BOARD
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18. INSTALL DECK BOARD ASSEMBLY
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19. INSPECT FOR FUEL LEAK
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20. PERFORM INITIALIZATION
(a) Perform "Inspection After Repair" after replacing the fuel pump.
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