A25A-FKS (FUEL): FUEL SENDER GAUGE ASSEMBLY (w/ Canister Pump Module): REMOVAL; 2023 MY RAV4 [10/2022

Last Modified: 05-08-2025	6.11:8.1.0	Doc ID: RM1000000026X2C
Model Year Start: 2023	Model: RAV4	Prod Date Range: [10/2022 - 10/2023]
Title: A25A-FKS (FUEL): FUEL SENDER GAUGE ASSEMBLY (w/ Canister Pump Module): REMOVAL; 2023 MY RAV4 [10/2022 - 10/2023]

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
*: When performing learning using the Techstream.
Battery terminal is disconnected/reconnected	Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)	Stop and start system
	Perform steering sensor zero point calibration	Lane control system
		Parking support brake system*
		Pre-collision system
	Reset back door close position	Power back door system
	Back door lock initialization	Power door lock control system

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 (-) 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.

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PROCEDURE

1. PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

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

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3. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

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4. REMOVE FUEL SENDER GAUGE ASSEMBLY

(a) Disconnect the 2 connectors from the fuel suction plate sub-assembly.

(b) Detach the 2 clamps 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.

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.

5. REMOVE REAR FLOOR SERVICE HOLE COVER (for RH Side)

(a) Remove the rear floor service hole cover and butyl tape.

(b) Disconnect the connector from the fuel tank vent tube assembly.

6. REMOVE FUEL PUMP GAUGE RETAINER

(a) Detach the claw and remove the No. 1 fuel tube clamp from the fuel pump gauge retainer.

(b) Remove the fuel pump gauge retainer.

(1) Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.

SST: 09808-01071

SST: 09808-14031

09808-01030

09808-01090

HINT:

Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.

*a	SST (Plate)
*b	SST (Bolt)
*c	SST (Claw)
*d	Insertion Point

(2) While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).

(3) Install SST (handle) to SST (plate).

SST: 09808-01071

SST: 09808-14031

09808-01010

09808-01030

09808-01090

*a	SST (Handle)
*b	SST (Bolt)
*c	SST (Plate)
*d	SST (Claw)

(4) Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing down on SST, rotate SST (handle) slowly to loosen the fuel pump gauge retainer.

NOTICE:

Do not use any tools other than specified in this operation as this may result in damage to the fuel pump gauge retainer or the 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.

(5) While pressing down on the fuel tank vent tube assembly, remove the fuel pump gauge retainer.

7. REMOVE FUEL TANK VENT TUBE ASSEMBLY

(a) Disconnect the fuel return vent tube sub-assembly and remove the fuel tank vent tube assembly from the fuel tank assembly.

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NOTICE:

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

(b) Remove the gasket from the fuel tank assembly.

8. REMOVE NO. 2 FUEL SENDER GAUGE ASSEMBLY

(a) Disconnect the connector from the fuel tank vent tube assembly.

(b) Detach the 2 clamps and disconnect the wire harness from the fuel tank vent tube assembly.