Toyota RAV4 manuals

Toyota RAV4 Service Manual: Fuel tank

Components

Toyota RAV4. Fuel tank


Toyota RAV4. Fuel tank


Removal

  1. Discharge fuel system pressure (see page fu-9)

  2. Disconnect cable from negative battery terminal

Caution:

Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

  1. Remove fuel tank cap

  2. Remove front floor cover

  1. Remove the nut, bolt, 3 clips and floor cover.
  1. Remove no. 1 Floor under cover

  1. Remove the 2 nuts, clip and floor under cover.

Toyota RAV4. Remove no. 1 Floor under cover


  1. Disconnect no. 2 Parking brake cable assembly

Toyota RAV4. Disconnect no. 2 Parking brake cable assembly


  1. Remove the 2 bolts and disconnect the parking brake cable.
  1. Disconnect fuel tank main tube subassembly

Toyota RAV4. Disconnect fuel tank main tube subassembly


  1. Pinch and pull the main tube connector to disconnect the connector from the pipe.

Notice:

  1. Disconnect the evap hose from the tank.
  1. Disconnect fuel tank to filler pipe hose

Toyota RAV4. Disconnect fuel tank to filler pipe hose


  1. Disconnect the filler pipe hose from the fuel tank.
  1. Disconnect fuel tank breather hose

Toyota RAV4. Disconnect fuel tank breather hose


  1. Disconnect the breather hose from the fuel tank.

Notice:

  1. Remove fuel tank filler pipe

  1. Remove the 3 bolts and filler pipe protector.
  2. Remove the 2 bolts and filler pipe.
  1. Remove fuel tank assembly

Toyota RAV4. Remove fuel tank assembly


  1. Set a mission jack underneath the fuel tank.
  2. Remove the 6 bolts and 3 fuel tank bands.
  3. Slightly lower the mission jack.

Notice:

Be careful not to cut the wirings.

Toyota RAV4. Remove fuel tank assembly


  1. Fold back approximately half of each cushion rubber so that the wire harness can be detached from the fuel tank in the step below.
  2. Disconnect the fuel pump connector and sender gauge connector.

Notice:

  1. Detach the wire harness from the 4 clamps and remove the fuel tank.

Disassembly

  1. Remove fuel tank main tube sub-assembly (see page fu-30)

  2. Remove fuel tank vent tube set plate (see page fu-30)

  3. Remove fuel suction with pump assembly (see page fu-30)

  4. Remove fuel tank main tube sub-assembly

  1. Remove the tube from the fuel tube clamps.
  1. Remove no. 1 Fuel tube clamp

Toyota RAV4. Remove no. 1 Fuel tube clamp


  1. Remove the 4 tube clamps from the fuel tank.
  1. Remove no. 1 Fuel tank cushion

Toyota RAV4. Remove no. 1 Fuel tank cushion


  1. Remove the 7 fuel tank cushions from the fuel tank.
  1. Remove fuel sender gauge assembly

Toyota RAV4. Remove fuel sender gauge assembly


  1. Remove the 5 screws and sender gauge.

Reassembly

  1. Install fuel sender gauge assembly

Toyota RAV4. Install fuel sender gauge assembly


  1. Install the sender gauge with the 5 bolts.

Torque: 1.5 N*m (15 kgf*cm, 13 in.*Lbf)

  1. Install no. 1 Fuel tank cushion

Toyota RAV4. Install no. 1 Fuel tank cushion


  1. Install 7 new fuel tank cushions onto the fuel tank as shown in the illustration.
  1. Install no. 1 Fuel tube clamp

Toyota RAV4. Install no. 1 Fuel tube clamp


  1. Install the 4 tube clamps to the fuel tank.
  1. Install fuel tank main tube sub-assembly

  1. Install the tube with the 4 clips.
  1. Install fuel suction with pump assembly (see page fu-36)

  2. Install fuel tank vent tube set plate (see page fu-36)

  3. Install fuel tank main tube sub-assembly (see page fu-37)

Installation

  1. Install fuel tank assembly

Toyota RAV4. Install fuel tank assembly


  1. Set the fuel tank on a mission jack.
  2. Lift up the mission jack.
  3. Fold back the 2 cushion rubbers.
  4. Connect the fuel pump connector and sender gauge connector to the fuel tank.

Notice:

Be careful not to cut the wirings.

  1. Attach the wire harness to the 4 clamps.
  2. Install the 3 fuel tank bands with the 6 bolts.

Torque: 40 n*m (408 kgf*cm, 30 ft.*Lbf)

  1. Install fuel tank filler pipe

Toyota RAV4. Install fuel tank filler pipe


  1. Install the filler pipe with the 2 bolts.

    Torque: 23.5 N*m (240 kgf*cm, 17 ft.*Lbf)

  2. Install the filler pipe protector with the 3 bolts.
  1. Connect fuel tank to filler pipe hose

Toyota RAV4. Connect fuel tank to filler pipe hose


  1. Connect the filler pipe hose to the fuel tank.
  1. Connect fuel tank breather hose

Toyota RAV4. Connect fuel tank breather hose


  1. Connect the fuel tank breather hose to the fuel tank.

Notice:

  1. Connect fuel tank main tube sub-assembly

Notice:

Before installing the tube connector to the pipe, check the connector for damage and foreign matter.

  1. Connect the main tube connector to the pipe. Push the 2 parts together firmly until a "click" sound is heard.

Notice:

Check that the connector and pipe are securely connected by trying to pull them apart.

  1. Connect the evap hose to the fuel tank.

Toyota RAV4. Connect fuel tank main tube sub-assembly


  1. Install no. 1 Floor under cover

  1. Install the floor cover with the clip and 2 nuts.

Toyota RAV4. Install no. 1 Floor under cover


  1. Install front floor cover

  1. Install the floor under cover with the 3 clips, bolt and nut.
  1. Install no. 2 Parking brake cable assembly

Toyota RAV4. Install no. 2 Parking brake cable assembly


  1. Install the parking brake cable with the 2 bolts.
  1. Install fuel tank cap

  2. Connect cable to negative battery terminal

  3. Check for fuel leaks (see page fu-14)

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 ...

2Az-fe lubrication
...

Other materials:

Horn system
Parts location System diagram Problem symptoms table Hint: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "suspected area" column of the table. Check each symptom by c ...

Removal
Caution: Be sure to read the precautionary notices concerning the srs airbag system before servicing it (see page rs-1). Disconnect cable from negative battery terminal Caution: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent air ...

Removal (2006/01- )
Disconnect cable from negative battery terminal Caution: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. Remove roof headlining assembly Remove the roof headlining (see page ir ...

В© 2011-2018 Copyright www.trav4.net