Toyota RAV4 Service Manual: Fuel pump
Components


Removal
- Remove fuel tank assembly
- Remove the fuel tank (see page fu-39).
- Remove fuel tank main tube sub-assembly
- Remove the joint clip and fuel tank main tube.

Caution:
- Before removing the tube joint clip, check for
foreign matter around the clip. Clean if
necessary.
- Keep the o-ring free of foreign matter, as it
becomes contaminated easily.
- Do not use any tools in this procedure.
- Do not forcefully bend or twist the tube.
- Put the tube in a plastic bag to prevent
damage and contamination.
- If the fuel suction plate and tube are stuck
together, pinch the tube and turn it carefully
to disconnect it.
- Be careful not to damage the clip. If the clip is
damaged, replace it.
- Remove fuel tank vent tube set plate

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

- Disconnect the fuel hose and remove the fuel pump
from the fuel tank.
Notice:
Do not damage the fuel pump.

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

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

Hint:
Slightly lower the sub-tank to remove the e-ring.
- Remove the 2 springs from the 2 shaft.

- Remove the 2 springs from the 2 shaft.

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

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

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

- Using a screwdriver, detach the 2 claws and remove
the bracket.
Hint:
Tape the screwdriver tip before use.
- Remove fuel pump assembly

- 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.

- Disconnect the fuel pump connector.

- Remove the o-ring from the fuel filter.
Inspection
- Inspect fuel pump

- Check the fuel pump resistance.
- Measure the resistance between terminals 1
and 2.
Standard resistance:
0.2 To 3.0 ٠at 20°c (68°f)
If the result is not as specified, replace the fuel
pump.
- Check fuel pump operation.
- Apply battery voltage to terminals 1 and 2.
Check that the pump operates.
Notice:
- These tests must be completed within 10
seconds to prevent the coil from burning
out.
- Keep the fuel pump as far away from the
battery as possible.
- Always the voltage on and off on the
battery side, not the fuel pump side.
If the pump does not operate, replace the fuel
pump.
Installation
- Install fuel pump assembly

- Connect the pump harness connector.

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

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

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

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

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

- Connect the wire harness.

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

- Using needle-nose pliers, install a new e-ring.
Hint:
Slightly lower the sub-tank to install the e-ring.
- Install fuel suction with pump assembly

- Install a new gasket onto the fuel pump.
Connect the fuel hose and install the fuel pump into
the fuel tank.

Notice:
Do not damage the fuel pump filter.
- Install fuel tank vent tube set plate

- Install the set plate with the 8 bolts.
Torque: 4.0 N*m (41 kgf*cm, 35 in.*Lbf)
- Install fuel tank main tube sub-assembly

- Install the fuel tube with the joint clips.
Caution:
- Check that there are no scratches or foreign
objects on the connecting parts.
- Check that the fuel tube joint is inserted
securely.
- Check that the fuel tube joint clip is on the
collars of the fuel tube joint.
- After installing the tube joint clip, check that
the fuel tube joint has not been pulled off.
- Be careful not to damage the clip. If the clip is
damaged, replace it.

Install fuel tank assembly
- Install the fuel tank (see page fu-44).
Components
Removal
Discharge fuel system pressure (see page
fu-9)
Disconnect cable from negative battery
terminal
Remove no. 1 Engine cover (see page es-410)
Remove air cleaner ...
Components
Removal
Discharge fuel system pressure (see page
fu-9)
Disconnect cable from negative battery
terminal
Caution:
Wait at least 90 seconds after disconnecting the
cabl ...
Other materials:
Terminals of ecu
Skid control ecu
Hint:
*1: W/ 16-inch disc
*2: W/ downhill assist control
*3: For 2wd (w/ auto lsd)
Check skid control ecu
Disconnect the a19 ecu connector.
Measure the voltage and resistance of the wire
harness side connector.
Hint:
The voltage cannot be measured ...
Diagnostic trouble code chart (2006/01- )
Hint:
When the air conditioning system functions properly, dtc
b1400/00 is output.
Hint:
*1: Dtc b1422/22 (compressor lock sensor circuit) is
indicated only for a currently occurring malfunction for 2grfe.
*2: Compressor and pulley for 2az-fe, compressor and
magnetic clutch for 2gr-fe ...
How to proceed with troubleshooting
Hint:
Use these procedures to troubleshoot the seat belt
warning system.
*: Use the intelligent tester.
Vehicle brought to workshop
Inspect battery voltage
Standard voltage:
11 to 14 v
If the voltage is below 11 v, recharge or replace the battery
before proceeding.
...