Toyota RAV4 (XA40) 2013-2018 Service Manual: Fuel tank
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
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
- Remove fuel tank cap
- Remove front floor cover
- Remove the nut, bolt, 3 clips and floor cover.
- Remove no. 1 Floor under cover
- Remove the 2 nuts, clip and floor under cover.

- Disconnect no. 2 Parking brake cable assembly

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

- Pinch and pull the main tube connector to
disconnect the connector from the pipe.
Notice:
- Disconnect the evap hose from the tank.
- Disconnect fuel tank to filler pipe hose

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

- Disconnect the breather hose from the fuel tank.
Notice:
- Remove fuel tank filler pipe
- Remove the 3 bolts and filler pipe protector.
- Remove the 2 bolts and filler pipe.
- Remove fuel tank assembly

- Set a mission jack underneath the fuel tank.
- Remove the 6 bolts and 3 fuel tank bands.
- Slightly lower the mission jack.
Notice:
Be careful not to cut the wirings.

- Fold back approximately half of each cushion
rubber so that the wire harness can be detached
from the fuel tank in the step below.
- Disconnect the fuel pump connector and sender
gauge connector.
Notice:
- Before this procedure, check the connector
for dirt, mud or other contamination.
- Do not use any tools in this procedure.
- Detach the wire harness from the 4 clamps and
remove the fuel tank.
Disassembly
- Remove fuel tank main tube sub-assembly
(see page fu-30)
- Remove fuel tank vent tube set plate (see
page fu-30)
- Remove fuel suction with pump assembly
(see page fu-30)
- Remove fuel tank main tube sub-assembly
- Remove the tube from the fuel tube clamps.
- Remove no. 1 Fuel tube clamp

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

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

- Remove the 5 screws and sender gauge.
Reassembly
- Install fuel sender gauge assembly

- Install the sender gauge with the 5 bolts.
Torque: 1.5 N*m (15 kgf*cm, 13 in.*Lbf)
- Install no. 1 Fuel tank cushion

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

- Install the 4 tube clamps to the fuel tank.
- Install fuel tank main tube sub-assembly
- Install the tube with the 4 clips.
- Install fuel suction with pump assembly
(see page fu-36)
- Install fuel tank vent tube set plate (see
page fu-36)
- Install fuel tank main tube sub-assembly
(see page fu-37)
Installation
- Install fuel tank assembly

- Set the fuel tank on a mission jack.
- Lift up the mission jack.
- Fold back the 2 cushion rubbers.
- Connect the fuel pump connector and sender gauge
connector to the fuel tank.
Notice:
Be careful not to cut the wirings.
- Attach the wire harness to the 4 clamps.
- Install the 3 fuel tank bands with the 6 bolts.
Torque: 40 n*m (408 kgf*cm, 30 ft.*Lbf)
- Install fuel tank filler pipe

- Install the filler pipe with the 2 bolts.
Torque: 23.5 N*m (240 kgf*cm, 17 ft.*Lbf)
- Install the filler pipe protector with the 3 bolts.
- Connect fuel tank to filler pipe hose

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

- Connect the fuel tank breather hose to the fuel tank.
Notice:
- Before installing the tube connector to the
pipe, check the connector for damage and
foreign matter.
- Check that the connector and pipe is securely
connected by trying to pull them apart.
- Connect fuel tank main tube sub-assembly
Notice:
Before installing the tube connector to the pipe,
check the connector for damage and foreign matter.
- 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.
- Connect the evap hose to the fuel tank.

- Install no. 1 Floor under cover
- Install the floor cover with the clip and 2 nuts.

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

- Install the parking brake cable with the 2 bolts.
- Install fuel tank cap
- Connect cable to negative battery
terminal
- Check for fuel leaks (see page fu-14)
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 ...
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 ...
On-vehicle inspection
Notice:
Perform the maf meter inspection according to the
procedures below.
Only replace the maf meter when both the long
ft#1 value and maf value in the data list (with the
engine stopped) are not within the normal operating
range.
Inspect mass air flow meter
Perform c ...
Front airbag sensor lh circuit malfunction
Description
The front airbag sensor lh consists of the diagnostic circuit, the frontal
deceleration sensor, etc.
If the center airbag sensor receives signals from the frontal deceleration
sensor, it determines whether or
not the srs should be activated.
Dtc b1615/14 is recorded when a ma ...