Toyota RAV4 manuals

Toyota RAV4 Service Manual: Fuel pump

Components

Toyota RAV4. Fuel pump


Toyota RAV4. Fuel pump


Removal

  1. Remove fuel tank assembly

  1. Remove the fuel tank (see page fu-39).
  1. Remove fuel tank main tube sub-assembly

  1. Remove the joint clip and fuel tank main tube.

Toyota RAV4. Remove fuel tank main tube sub-assembly


Caution:

  1. Remove fuel tank vent tube set plate

Toyota RAV4. Remove fuel tank vent tube set plate


  1. Remove the 8 bolts and set plate.
  1. Remove fuel suction with pump assembly

Toyota RAV4. Remove fuel suction with pump assembly


  1. Disconnect the fuel hose and remove the fuel pump from the fuel tank.

Notice:

Do not damage the fuel pump.

Toyota RAV4. Remove fuel suction with pump assembly


  1. Remove the gasket from the fuel pump.
  1. Remove fuel sub-tank assembly

Toyota RAV4. Remove fuel sub-tank assembly


  1. disconnect the wire harness.
  2. Using needle nose pliers, remove the e-ring.

Toyota RAV4. Remove fuel sub-tank assembly


Hint:

Slightly lower the sub-tank to remove the e-ring.

  1. Remove the 2 springs from the 2 shaft.

Toyota RAV4. Remove fuel sub-tank assembly


  1. Remove the 2 springs from the 2 shaft.

Toyota RAV4. Remove fuel sub-tank assembly


  1. Detach the 2 claws and remove the sub-tank.

Toyota RAV4. Remove fuel sub-tank assembly


  1. Disengage the claw of the jet pump nozzle.
  2. Using a screwdriver with the tip taped, remove the jet pump.

Toyota RAV4. Remove fuel sub-tank assembly


  1. Remove the o-ring from the jet pump.
  1. Remove bracket

Toyota RAV4. Remove bracket


  1. Using a screwdriver, detach the 2 claws and remove the bracket.

Hint:

Tape the screwdriver tip before use.

  1. Remove fuel pump assembly

Toyota RAV4. Remove fuel pump assembly


  1. Detach the 5 claws on the filter and remove the fuel pump from the fuel filter.

Hint:

When removing the claw, do not disconnect the fuel main tube.

Toyota RAV4. Remove fuel pump assembly


  1. Disconnect the fuel pump connector.

Toyota RAV4. Remove fuel pump assembly


  1. Remove the o-ring from the fuel filter.

Inspection

  1. Inspect fuel pump

Toyota RAV4. Inspect fuel pump


  1. Check the fuel pump resistance.
  1. Measure the resistance between terminals 1 and 2.

Standard resistance: 0.2 To 3.0 Ù at 20°c (68°f)

If the result is not as specified, replace the fuel pump.

  1. Check fuel pump operation.
  1. Apply battery voltage to terminals 1 and 2.

    Check that the pump operates.

Notice:

If the pump does not operate, replace the fuel pump.

Installation

  1. Install fuel pump assembly

Toyota RAV4. Install fuel pump assembly


  1. Connect the pump harness connector.

Toyota RAV4. Install fuel pump assembly


  1. Apply gasoline to a new o-ring and install the o-ring to the fuel filter.
  2. Attach the 5 claws to the claw holes and install the fuel pump.
  1. Install bracket

Toyota RAV4. Install bracket


  1. Attach the 2 claws to the claw holes and install the bracket.
  1. Install fuel sub-tank assembly

Toyota RAV4. Install fuel sub-tank assembly


  1. Apply gasoline to a new o-ring and install it to the jet pump.

Toyota RAV4. Install fuel sub-tank assembly


  1. Install the jet pump while aligning it to the installation position of the sub-tank.
  2. Install the jet pump nozzle.

Toyota RAV4. Install fuel sub-tank assembly


  1. Attach the 2 claws to the claw holes and install the fuel sub-tank.

Toyota RAV4. Install fuel sub-tank assembly


  1. Connect the wire harness.

Toyota RAV4. Install fuel sub-tank assembly


  1. Install the spring to the fuel suction plate shaft and install them to the sub-tank.

Toyota RAV4. Install fuel sub-tank assembly


  1. Using needle-nose pliers, install a new e-ring.

Hint:

Slightly lower the sub-tank to install the e-ring.

  1. Install fuel suction with pump assembly

Toyota RAV4. Install fuel suction with pump assembly


  1. Install a new gasket onto the fuel pump.

Connect the fuel hose and install the fuel pump into the fuel tank.

Toyota RAV4. Install fuel suction with pump assembly


Notice:

Do not damage the fuel pump filter.

  1. Install fuel tank vent tube set plate

Toyota RAV4. Install fuel tank vent tube set plate


  1. Install the set plate with the 8 bolts.

Torque: 4.0 N*m (41 kgf*cm, 35 in.*Lbf)

  1. Install fuel tank main tube sub-assembly

Toyota RAV4. Install fuel tank main tube sub-assembly


  1. Install the fuel tube with the joint clips.

Caution:

Toyota RAV4. Install fuel tank main tube sub-assembly


Install fuel tank assembly

  1. Install the fuel tank (see page fu-44).
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