| Last Modified: 01-30-2024 | 6.11:8.1.0 | Doc ID: RM100000001FHNU |
| Model Year Start: 2019 | Model: RAV4 | Prod Date Range: [11/2018 - ] |
| Title: A25A-FKS (FUEL): FUEL TANK (w/ Canister Pump Module): INSTALLATION; 2019 - 2024 MY RAV4 [11/2018 - ] | ||
INSTALLATION
PROCEDURE
1. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
(a) Attach the 4 clips and install the No. 1 fuel tank protector sub-assembly to the fuel tank assembly.
2. INSTALL NO. 1 FUEL TANK CUSHION
(a) Install 2 new No. 1 fuel tank cushions to the fuel tank assembly.
3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Attach the clamp and install the fuel tank main tube sub-assembly to the fuel tank assembly.
4. INSTALL FUEL TANK ASSEMBLY
CAUTION:
The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank assembly may fall off the engine lifter.
(a) Set the fuel tank assembly on an engine lifter.
NOTICE:
Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal.
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(b) Using the engine lifter, slowly raise the fuel tank assembly, and temporarily install the fuel tank assembly and 2 fuel tank band sub-assemblies with the 2 bolts in the order shown in the illustration. NOTICE:
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(c) Using SST, tighten the 4 bolts in the order shown in the illustration.
SST: 09961-00950
Torque:
Specified tightening torque
45 N*m (459 kgf*cm, 33 ft.*lbf)
HINT:
- Using SST, install the rear side of the fuel tank band.
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Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here
![2019 - 2024 MY RAV4 RAV4 HV [11/2018 - ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION](/t3Portal/stylegraphics/info.gif)
- When using SST (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
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*a |
LH Side |
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*b |
RH Side |
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*c |
Torque Wrench Fulcrum Length |
5. CONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY
(a) Connect the fuel tank filler pipe sub-assembly to the fuel tank filler pipe assembly.
Click here
6. CONNECT FUEL TANK BREATHER TUBE
(a) Connect the fuel tank breather tube to the fuel tank filler pipe assembly.
Click here
7. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Connect the fuel tank main tube sub-assembly to the fuel tube.
Click here
8. CONNECT FUEL TANK VENT TUBE
(a) Attach the clamp and connect the fuel tank vent tube.
(b) Connect the fuel tank vent tube to the fuel tank vent hose sub-assembly.
Click here
9. INSTALL NO. 1 FUEL TANK PROTECTOR
(a) Install the No. 1 fuel tank protector to the fuel tank band with the 2 nuts.
Torque:
10.5 N·m {107 kgf·cm, 8 ft·lbf}
10. INSTALL NO. 1 FLOOR UNDER COVER
(a) Install the No. 1 floor under cover to the body and tighten the nut.
(b) Attach the 3 clips and install the 2 bolts.
Torque:
7.5 N·m {76 kgf·cm, 66 in·lbf}
11. INSTALL FRONT FLOOR COVER RH
(a) Install the front floor cover RH to the body and tighten the 3 nuts.
(b) Attach the 2 clips and install the 2 bolts and 4 screws.
Torque:
7.5 N·m {76 kgf·cm, 66 in·lbf}
12. INSTALL NO. 2 FLOOR UNDER COVER
(a) Install the No. 2 floor under cover to the body and tighten the 4 nuts.
(b) Attach the 3 clips and install the 2 bolts.
Torque:
7.5 N·m {76 kgf·cm, 66 in·lbf}
13. INSTALL FRONT FLOOR COVER LH
(a) Install the front floor cover LH to the body and tighten the 3 nuts.
(b) Attach the 3 clips and install the 2 bolts and 5 screws.
Torque:
7.5 N·m {76 kgf·cm, 66 in·lbf}
14. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY
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15. INSTALL NO. 1 ENGINE UNDER COVER
Click here
16. INSTALL FRONT FENDER FRONT SPLASH SHIELD RH
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17. INSTALL FRONT FENDER FRONT SPLASH SHIELD LH
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18. INSTALL PROPELLER SHAFT ASSEMBLY (for AWD)
Click here
19. INSTALL TAIL EXHAUST PIPE ASSEMBLY
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20. ADD FUEL
21. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
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22. INSTALL FUEL TANK VENT TUBE ASSEMBLY
Click here
23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
Click here
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