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:
Using the radio
Power
Volume
Adjusting the frequency
Scanning for receivable stations
Am/fm mode button
Station selectors
Seeking the frequency
Displaying text message
Setting station presets
Search for the desired stations by turning the ¢Â§tune¢escroll¢¸
knob or ...
Brake
General maintenance
Inspect brake lines and hoses
Hint:
Work in a well-lighted area. Turn the front wheels fully to
the right or left before beginning the inspection.
Using a mirror, check the entire circumference and
length of the brake lines and hoses for:
Damage
Wear
...
Side collision mitigation- Switching on/off
Switching on automatically
The side collision mitigation activates automatically
after departure if the function was switched
on at the end of the last trip.
Switching on manually
Press the button.
The menu for the Intelligent Safety system
is displayed.
If all Intelligent Safety systems were swit ...