| Last Modified: 05-08-2025 | 6.11:8.1.0 | Doc ID: RM100000001WM8O |
| Model Year Start: 2021 | Model: RAV4 | Prod Date Range: [08/2020 - 12/2021] |
| Title: A25A-FKS (FUEL): FUEL TANK (w/ Canister Pump Module): REMOVAL; 2021 MY RAV4 [08/2020 - 12/2021] | ||
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 tank assembly removal/installation are shown below.
Necessary Procedures After Parts Removed/Installed/Replaced
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Replaced Part or Performed Procedure |
Necessary Procedure |
Effect/Inoperative Function when Necessary Procedure not Performed |
Link |
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*: When performing learning using the Techstream.
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Battery terminal is disconnected/reconnected |
Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes) |
Stop and start system |
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Perform steering sensor zero point calibration |
Lane control system |
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Parking support brake system* |
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Pre-collision system |
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Memorize steering angle neutral point |
Parking assist monitor system |
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Panoramic view monitor system |
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Reset back door close position |
Power back door system |
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Back door lock initialization |
Power door lock control system |
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CAUTION:
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Never perform work on fuel system components near any possible ignition sources.
- Vaporized fuel could ignite, resulting in a serious accident.
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Do not perform work on fuel system components without first disconnecting the cable from the negative (-) battery terminal.
- Sparks could cause vaporized fuel to ignite, resulting in a serious accident.
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The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank assembly may fall off the engine lifter.
NOTICE:
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.
Click here
![2021 - 2025 MY RAV4 [08/2020 - ]; A25A-FKS (FUEL): FUEL SYSTEM: PRECAUTION](/t3Portal/stylegraphics/info.gif)
PROCEDURE
1. PRECAUTION
NOTICE:
After turning the ignition 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.
Click here
2. DISCHARGE FUEL SYSTEM PRESSURE
Click here
3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
Click here
4. REMOVE FUEL TANK VENT TUBE ASSEMBLY
Click here
5. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
Click here
6. DRAIN FUEL
7. REMOVE TAIL EXHAUST PIPE ASSEMBLY
Click here
8. REMOVE PROPELLER SHAFT ASSEMBLY (for AWD)
Click here
9. REMOVE FRONT FENDER FRONT SPLASH SHIELD LH
Click here
10. REMOVE FRONT FENDER FRONT SPLASH SHIELD RH
Click here
11. REMOVE NO. 1 ENGINE UNDER COVER
Click here
12. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY
Click here
13. REMOVE FRONT FLOOR COVER LH
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(a) Detach the 3 clips and remove the 2 bolts and 5 screws. |
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(b) Loosen the 3 nuts and remove the front floor cover LH from the body. |
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14. REMOVE NO. 2 FLOOR UNDER COVER
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(a) Detach the 3 clips and remove the 2 bolts. |
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(b) Loosen the 4 nuts and remove the No. 2 floor under cover from the body. |
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15. REMOVE FRONT FLOOR COVER RH
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(a) Detach the 2 clips and remove the 2 bolts and 4 screws. |
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(b) Loosen the 3 nuts and remove the front floor cover RH from the body. |
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16. REMOVE NO. 1 FLOOR UNDER COVER
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(a) Detach the 3 clips and remove the 2 bolts. |
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(b) Loosen the nut and remove the No. 1 floor under cover from the body. |
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17. REMOVE NO. 1 FUEL TANK PROTECTOR
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(a) Remove the 2 nuts and No. 1 fuel tank protector from the fuel tank band. |
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18. DISCONNECT FUEL TANK VENT TUBE
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(a) Disconnect the fuel tank vent tube from the fuel tank vent hose sub-assembly. Click here
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(b) Detach the clamp and disconnect the fuel tank vent tube.
19. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
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(a) Disconnect the fuel tank main tube sub-assembly from the fuel tube. Click here
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20. DISCONNECT FUEL TANK BREATHER TUBE
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(a) Disconnect the fuel tank breather tube from the fuel tank filler pipe assembly. Click here
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21. DISCONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY
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(a) Disconnect the fuel tank filler pipe sub-assembly from the fuel tank filler pipe assembly. Click here
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22. REMOVE FUEL TANK ASSEMBLY
CAUTION:
The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank assembly may fall off the engine lifter.
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(a) Using an engine lifter, support the fuel tank assembly. HINT: Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal. |
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(b) Remove the 4 bolts and 2 fuel tank band sub-assemblies. |
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(c) Lower the engine lifter to remove the fuel tank assembly.
NOTICE:
- 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.
23. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
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(a) Detach the clamp and remove the fuel tank main tube sub-assembly from the fuel tank assembly. |
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24. REMOVE NO. 1 FUEL TANK CUSHION
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(a) Remove the 2 No. 1 fuel tank cushions from the fuel tank assembly. |
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25. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
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(a) Detach the 4 clips and remove the No. 1 fuel tank protector sub-assembly from the fuel tank assembly. |
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