A25A-FKS (FUEL): FUEL PUMP (w/ Canister Pump Module): INSTALLATION; 2019 - 2024 MY RAV4 [11/2018

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000001FHNG
Model Year Start: 2019	Model: RAV4	Prod Date Range: [11/2018 - ]
Title: A25A-FKS (FUEL): FUEL PUMP (w/ Canister Pump Module): INSTALLATION; 2019 - 2024 MY RAV4 [11/2018 - ]

INSTALLATION

PROCEDURE

1. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

(a) Install a new gasket to the fuel tank assembly.

(b) Connect the fuel return vent tube sub-assembly and set the fuel suction with pump and gauge tube assembly to the fuel tank assembly.

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NOTICE:

Make sure to correctly assemble the fuel return vent tube sub-assembly as shown in the illustration. If assembled incorrectly, the fuel sender gauge assembly (No. 2 fuel sender gauge assembly) may catch on the fuel return vent tube resulting in incorrect operation of the fuel sender gauge assembly (No. 2 fuel sender gauge assembly) and an incorrect value being displayed on the fuel gauge.

*a	Fuel Return Vent Tube Sub-assembly
	Front of the Vehicle

Be careful not to bend the arm of the fuel sender gauge assembly.
To avoid applying excessive force to the tip of the fuel sender gauge assembly, tilt the fuel sub-tank sub-assembly diagonally and insert it into the fuel tank assembly as shown in the illustration.

*1	Plate Sub-assembly	*2	Fuel Sub-tank Sub-assembly
*3	Fuel Sender Gauge Assembly	-	-

(c) Align the protrusions of the fuel suction with pump and gauge tube assembly with the notches in the fuel tank assembly.

*a	Protrusion
*b	Notch

2. INSTALL FUEL PUMP GAUGE RETAINER

(a) Install the fuel pump gauge retainer.

(1) While pressing down on the fuel suction with pump and gauge tube assembly, temporarily install the fuel pump gauge retainer.

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

SST: 09808-14031

09808-01030

09808-01090

SST: 09808-01071

HINT:

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

*a	SST (Plate)
*b	SST (Bolt)
*c	SST (Claw)
*d	Insertion Point

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

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

SST: 09808-14031

09808-01010

09808-01030

09808-01090

SST: 09808-01071

*a	SST (Handle)
*b	SST (Plate)
*c	SST (Bolt)
*d	Triangle Mark (Fuel Pump Gauge Retainer)
*e	Triangle Mark (Fuel Tank Assembly)

(5) Using SST, rotate the fuel pump gauge retainer so that the triangle mark on the fuel pump gauge retainer is aligned with the triangle mark on the fuel tank assembly to install the fuel suction with pump and gauge tube assembly to the fuel tank assembly.

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.
Make sure that the fuel suction tube set gasket does not come off.

(b) Attach the claw to install the No. 1 fuel tube clamp to the fuel pump gauge retainer.

3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Push the fuel tube joint of the fuel tank main tube sub-assembly, and install the tube joint clip.

NOTICE:

Check that there are no scratches or foreign matter around the connecting parts of the fuel tube joint and plug before performing this work.
Check that the fuel tube joint is securely inserted to the end.
Check that the tube joint clip is on the collar of the fuel tube joint.
After installing the tube joint clip, check that the fuel tank main tube sub-assembly is securely connected by pulling on it.

*1	Tube Joint Clip
*a	Nylon Tube
*b	Fuel Tube Joint
*c	O-ring
*d	Correct
*e	Incorrect

4. INSTALL REAR FLOOR SERVICE HOLE COVER (for LH Side)

(a) Remove any remaining butyl tape from the rear floor service hole cover and body.

(b) Connect the 2 connectors to the fuel suction with pump and gauge tube assembly.

NOTICE:

Securely install the rear floor service hole cover.

5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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6. INSPECT FOR FUEL LEAK

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7. INSTALL REAR SEAT CUSHION LOCK HOOK

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8. INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY

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9. PERFORM INITIALIZATION

(a) Perform "Inspection After Repair" after replacing the fuel pump.

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