Toyota RAV4 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:
Brake master cylinder
Components
On-vehicle inspection
Check brake fluid level warning switch
Remove the reservoir filler cap and strainer.
Disconnect the brake fluid level warning switch
connector.
Measure the resistance of the switch.
Hint:
There is a float inside the reservoir. Its positio ...
Tire pressure warning ecu
Components
Removal
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 glove compartment door
assembly (see page i ...
Disassembly
Fix differential carrier sub-assembly
Fix the rear differential carrier in place with the
overhaul attachment.
Remove stud bolt
Remove the 4 stud bolts from the transmission
coupling.
Remove differential drain plug
Using a 10 mm socket hexagon wrench, remove ...