Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001WM8U
Model Year Start: 2021 Model: RAV4 HV Prod Date Range: [08/2020 - 12/2021]
Title: A25A-FXS (FUEL): FUEL SENDER GAUGE ASSEMBLY (w/ Canister Pump Module): REMOVAL; 2021 MY RAV4 HV [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 sender gauge 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
*: When performing learning using the Techstream.

Click here 2019 - 2022 MY RAV4 HV [02/2019 - 10/2022]; PARK ASSIST / MONITORING: PARKING SUPPORT BRAKE SYSTEM (for HV Model): CALIBRATION

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

Parking support brake system*

Pre-collision system

Lighting system (EXT) (w/ AFS)

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

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.

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 - 2024 MY RAV4 HV [08/2020 -        ]; A25A-FXS (FUEL): FUEL SYSTEM: 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. REMOVE DECK BOARD ASSEMBLY

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+

3. REMOVE REAR NO. 2 FLOOR BOARD

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+

4. REMOVE BATTERY HOLE COVER

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+

5. 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 2021 MY RAV4 RAV4 HV [08/2020 - 12/2021]; INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION

6. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; A25A-FXS (FUEL): FUEL PUMP (w/ Canister Pump Module): REMOVAL

7. REMOVE FUEL SENDER GAUGE ASSEMBLY

(a) Disconnect the 3 connectors from the fuel suction plate sub-assembly.

(b) Detach the clamp and disconnect the wire harness.

NOTICE:

  • Do not damage the wire harness.
  • When disengaging each wire harness from the clamp, disengage one wire at a time.

(c) Detach the clamp and disconnect the wire harness.

NOTICE:

  • Do not damage the wire harness.
  • When disengaging each wire harness from the clamp, disengage one wire at a time.

(d) Detach the 2 claws and remove the fuel sender gauge assembly.

NOTICE:

Be careful not to bend the arm of the fuel sender gauge assembly.