A25A-FXS (FUEL): FUEL PUMP (w/ Canister Pump Module): REMOVAL; 2024 MY RAV4 HV [10/2023

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000002FR43
Model Year Start: 2024	Model: RAV4 HV	Prod Date Range: [10/2023 - ]
Title: A25A-FXS (FUEL): FUEL PUMP (w/ Canister Pump Module): REMOVAL; 2024 MY RAV4 HV [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 pump 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. Click here
Auxiliary battery terminal is disconnected/reconnected	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
Replacement of fuel pump	Inspection after repair	Poor idle, etc. Engine start function, etc.

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.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the power 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.

Click here

2. DISCHARGE FUEL SYSTEM PRESSURE

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3. REMOVE DECK BOARD ASSEMBLY

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4. REMOVE REAR NO. 2 FLOOR BOARD

Click here

5. REMOVE BATTERY HOLE COVER

Click here

6. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

NOTICE:

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

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7. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY

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8. REMOVE REAR SEAT CUSHION LOCK HOOK

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9. REMOVE REAR DOOR SCUFF PLATE LH

Click here

10. REMOVE NO. 3 BATTERY SERVICE COVER BOARD

Click here

11. REMOVE REAR DOOR SCUFF PLATE RH

HINT:

Use the same procedure as for the LH side.

12. REMOVE NO. 2 BATTERY SERVICE COVER BOARD

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13. REMOVE BATTERY SERVICE COVER BOARD

Click here

14. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY

Click here

15. REMOVE REAR FLOOR SERVICE HOLE COVER

(a) Fold back the floor carpet.

(b) Remove the 3 bolts and rear floor service hole cover.

16. REMOVE FUEL TANK PRESSURE SENSOR

Click here

17. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY

(a) Disconnect the fuel tank vent hose sub-assembly from the fuel suction with pump and gauge tube assembly.

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18. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.

NOTICE:

Remove any foreign matter on the fuel tube joint before performing this work.
Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
Be sure to disconnect the fuel tube joint by hand.
Do not bend, twist, pinch or kink the nylon tube.
Cover the disconnected fuel tube joint with a plastic bag to prevent damage and contamination.
If the fuel tube joint and plate sub-assembly are stuck, push and pull to release them.

*1	Tube Joint Clip
*2	Fuel Tank Main Tube Sub-assembly
*a	Nylon Tube
*b	Fuel Tube Joint
*c	Plate Sub-assembly
*d	O-ring
	Pull off
	Pull off

19. REMOVE FUEL PUMP GAUGE RETAINER

(a) Detach the claw and remove the fuel sender gauge wire from the fuel pump gauge retainer.

(b) Detach the claw and remove the No. 1 fuel tube clamp from 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) and an extension bar to SST (plate).

SST: 09808-01071

SST: 09808-14031

09808-01010

09808-01030

09808-01090

*a	SST (Handle)
*b	Extension Bar
*c	SST (Bolt)
*d	SST (Plate)
*e	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.

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 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 suction with pump and gauge tube assembly, remove the fuel pump gauge retainer.

20. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

(a) Remove the fuel suction with pump and gauge tube assembly from the fuel tank assembly.

NOTICE:

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

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