Last Modified: 08-21-2023 6.11:8.1.0 Doc ID: RM100000001B4M1
Model Year Start: 2019 Model: Avalon HV Prod Date Range: [04/2018 - 08/2021]
Title: A25A-FXS (FUEL): FUEL PUMP: REMOVAL; 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during fuel pump removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

*: When performing learning using the Techstream.

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: INTELLIGENT CLEARANCE SONAR SYSTEM (for HV Model): CALIBRATION

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane Departure Alert System (w/ Steering Control)

2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; PRE-COLLISION: PRE-COLLISION SYSTEM (for HV Model): INITIALIZATION

Pre-collision System

Intelligent Clearance Sonar System*

Lighting System (for HV Model with Cornering Light)

Memorize steering angle neutral point

Parking Assist Monitor System

2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM(for HV Model): INITIALIZATION

Panoramic View Monitor System

2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): INITIALIZATION

Replacement of fuel pump

Inspection after repair

  • Poor idle, etc.
  • Engine start function, etc.

2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

CAUTION:

  • Never perform work on fuel system components near any possible ignition sources.
  • Vaporized fuel could ignite, resulting in a serious accident.
  • Do not perform work on fuel system components without first disconnecting the cable from the negative (-) auxiliary battery terminal.
  • Sparks could cause vaporized fuel to ignite, resulting in a serious accident.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

2. DISCHARGE FUEL SYSTEM PRESSURE

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

3. REMOVE LUGGAGE TRIM SERVICE HOLE COVER

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+

4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+

5. REMOVE REAR SEAT ASSEMBLY

Click here 2019 - 2020 MY Avalon Avalon HV [04/2018 - 08/2020]; SEAT: REAR SEAT ASSEMBLY: REMOVAL 2021 MY Avalon Avalon HV [08/2020 - 08/2021]; SEAT: REAR SEAT ASSEMBLY: REMOVAL

6. REMOVE CENTER REAR SEATBACK HINGE SUB-ASSEMBLY

(a) Remove the 2 bolts and center rear seatback hinge sub-assembly from the vehicle body.

7. REMOVE REAR FLOOR SERVICE HOLE COVER

(a) Using a clip remover with its tip wrapped with protective tape, remove the rear floor service hole cover and butyl tape.

*a

Protective Tape

(b) Disconnect the 2 fuel pump connectors and fuel tank pressure sensor (vapor pressure sensor assembly) connector.

8. REMOVE FUEL TANK PRESSURE SENSOR (VAPOR PRESSURE SENSOR ASSEMBLY)

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (EMISSION CONTROL): FUEL TANK PRESSURE SENSOR: REMOVAL+

9. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY

(a) Disconnect the fuel tank vent hose sub-assembly from the fuel suction tube with pump and gauge assembly.

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

10. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.

*1

Fuel Suction Plate Sub-assembly

*2

Tube Joint Clip

*3

Fuel Tank Main Tube Sub-assembly

*a

Fuel Tube Joint

*b

O-ring

*c

Nylon Tube

Pull off

Pull off

NOTICE:

  • Remove any foreign matter on the fuel tube joint before performing this work.
  • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
  • Be sure to disconnect the fuel tube joint by hand.
  • Do not bend, twist, pinch or kink the nylon tube.
  • Cover the disconnected fuel tube joint with a plastic bag to prevent damage and contamination.
  • If the fuel tube joint and fuel suction plate sub-assembly are stuck, push and pull to release them.

11. REMOVE FUEL PUMP GAUGE RETAINER

(a) Disengage the claw to remove the No. 1 fuel tube clamp.

(b) Remove the fuel pump gauge retainer.

(1) Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.

SST: 09808-14031

09808-01030

09808-01050

SST: 09808-01071

HINT:

Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.

*a

Insertion Point

*b

SST (Plate)

*c

SST (Claw)

*d

SST (Bolt)

(2) While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).

(3) Install SST (handle) to SST (plate).

SST: 09808-14031

09808-01010

SST: 09808-01071

*a

SST (Handle)

*b

SST (Plate)

*c

SST (Claw)

*d

SST (Bolt)

(4) Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing down on SST, rotate SST (handle) slowly to loosen the fuel pump gauge retainer.

NOTICE:

  • Do not use any tools other than specified as this may result in damage to the fuel pump gauge retainer or fuel tank assembly.
  • Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
  • Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.
  • Do not spin SST too fast or use an impact wrench as this may result in damage to components.
  • If SST comes off of the fuel pump gauge retainer, loosen SST (bolt) and reinstall SST.

(5) While pressing down on the fuel suction tube with pump and gauge assembly, remove the fuel pump gauge retainer.

12. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

(a) Raise the fuel suction tube with pump and gauge assembly.

(b) Set the part (A) of the fuel suction tube with pump and gauge assembly against the fuel tank assembly, and remove the fuel suction tube with pump and gauge assembly from the fuel tank assembly as shown in the illustration.

NOTICE:

Be careful not to bend the arm of the fuel sender gauge assembly.

(c) Remove the fuel suction tube set gasket from the fuel tank assembly.