A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION; 2019 - 2020 MY RAV4 HV [02/2019

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000001HH3B
Model Year Start: 2019	Model: RAV4 HV	Prod Date Range: [02/2019 - 08/2020]
Title: A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION; 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]

PRECAUTION

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.
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.
To prevent serious injury due to fuel spray from the high-pressure fuel lines, always discharge fuel system pressure before removing any fuel system components.

BEFORE WORKING ON FUEL SYSTEM

(a) Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) auxiliary battery terminal.

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

(b) Do not smoke or work near fire when handling the fuel system.

CAUTION:

Make sure the engine coolant temperature is 60°C (140°F) or less when performing this procedure.
Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
Pressure will still remain in the fuel lines even after performing the following procedure. When disconnecting a fuel line, cover it with a piece of cloth to prevent fuel from spraying or coming out.

DISCHARGE FUEL SYSTEM PRESSURE

(a) When discharging fuel system pressure by disconnecting the EFI MAIN NO. 2 relay:

(1) Remove the engine room relay block cover.

(2) Remove the EFI MAIN NO. 2 relay.

(3) Remove the front fender front splash shield LH.

Click here

(4) Remove the front fender front splash shield RH.

Click here

(5) Remove the No. 1 engine under cover.

Click here

(6) Remove the No. 2 engine under cover assembly.

Click here

(7) Detach the claw and raise the lock lever to disconnect the No. 6 engine wire connector as shown in the illustration.

*a	Lock Lever

(8) Connect the Techstream to the DLC3.

(9) Turn the power switch on (IG).

(10) Turn the Techstream on.

(11) Put the engine in Inspection Mode (Maintenance Mode).

Powertrain > Hybrid Control > Utility

Tester Display
Inspection Mode

(12) Start the engine. After the engine has stopped on its own, turn the power switch off.

NOTICE:

Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

(13) Crank the engine again and make sure that the engine does not start.

HINT:

DTC P008700 (Fuel Rail / System Pressure - Too Low), P017100 (System Too Lean), P319000 (Poor Engine Power), P319100 (Engine does not Start) or P319300 (Fuel Run Out) may be stored. Clear the DTCs before proceeding to the next step.

SFI system (w/ Canister Pump Module):
Click here
SFI system (w/o Canister Pump Module):
Click here
Hybrid control system DTC (for NICKEL METAL HYDRIDE BATTERY):
Click here
Hybrid control system DTC (for LITHIUM-ION BATTERY):
Click here

(14) Remove the fuel tank cap assembly and discharge the pressure from the fuel tank assembly.

(15) Disconnect the cable from the negative (-) auxiliary battery terminal.

NOTICE:

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

Click here

(16) Connect the No. 6 engine wire connector and push down the lock lever to attach the claw as shown in the illustration.

*a	Lock Lever

(17) Install the No. 2 engine under cover assembly.

Click here

(18) Install the No. 1 engine under cover.

Click here

(19) Install the front fender front splash shield LH.

Click here

(20) Install the front fender front splash shield RH.

Click here

(21) Install the EFI MAIN NO. 2 relay.

(22) Install the engine room relay block cover.

(b) When discharging fuel system pressure by disconnecting the fuel pump connector:

(1) Remove the bench type rear seat cushion assembly.

Click here

(2) Remove the rear seat cushion lock hook.

Click here

(3) Remove the rear door scuff plate LH.

Click here

(4) Remove the No. 3 battery service cover board.

Click here

(5) Remove the rear door scuff plate RH.

(6) Remove the No. 2 battery service cover board.

Click here

(7) Remove the battery service cover board.

Click here

(8) Remove the 3 bolts and rear floor service hole cover.

(9) Disconnect the connector from the fuel suction with pump and gauge tube assembly.

*A	w/ Canister Pump Module
*B	w/o Canister Pump Module

(10) Remove the front fender front splash shield LH.

Click here

(11) Remove the front fender front splash shield RH

Click here

(12) Remove the No. 1 engine under cover.

Click here

(13) Remove the No. 2 engine under cover assembly.

Click here

(14) Detach the claw and raise the lock lever to disconnect the No. 6 engine wire connector as shown in the illustration.

*a	Lock Lever

(15) Connect the Techstream to the DLC3.

(16) Turn the power switch on (IG).

(17) Turn the Techstream on.

(18) Put the engine in Inspection Mode (Maintenance Mode).

Powertrain > Hybrid Control > Utility

Tester Display
Inspection Mode

(19) Start the engine. After the engine has stopped on its own, turn the power switch off.

NOTICE:

Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

(20) Crank the engine again and make sure that the engine does not start.

HINT:

SFI system (w/ Canister Pump Module):
Click here
SFI system (w/o Canister Pump Module):
Click here
Hybrid control system DTC (for NICKEL METAL HYDRIDE BATTERY):
Click here
Hybrid control system DTC (for LITHIUM-ION BATTERY):
Click here

(21) Remove the fuel tank cap assembly and discharge the pressure from the fuel tank assembly.

(22) Disconnect the cable from the negative (-) auxiliary battery terminal.

NOTICE:

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

Click here

(23) Connect the No. 6 engine wire connector and push down the lock lever to attach the claw as shown in the illustration.

*a	Lock Lever

(24) Install the No. 2 engine under cover assembly.

Click here

(25) Install the No. 1 engine under cover.

Click here

(26) Install the front fender front splash shield LH.

Click here

(27) Install the front fender front splash shield RH.

Click here

(28) Connect the connector to the fuel suction with pump and gauge tube assembly.

(29) Install the rear floor service hole cover with the 3 bolts.

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

NOTICE:

Securely install the rear floor service hole cover.

(30) Install the battery service cover board.

Click here

(31) Install the No. 2 battery service cover board.

Click here

(32) Install the rear door scuff plate RH.

(33) Install the No. 3 battery service cover board.

Click here

(34) Install the rear door scuff plate LH.

Click here

(35) Install the rear seat cushion lock hook.

Click here

(36) Install the bench type rear seat cushion assembly.

Click here

FUEL LINE

(a) When disconnecting a high-pressure fuel line, a large amount of fuel will spray. Perform the following procedure:

(1) Discharge fuel system pressure.

(2) Disconnect the fuel tube.

(3) Drain the fuel remaining inside the fuel pump tube into a container.

(4) Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

(b) Quick Type A:

Perform the following procedure when disconnecting a fuel tube connector.

NOTICE:

Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

(1) Clamp Type A (No. 1 Fuel Pipe Clamp):

	Open
	Pull

Open the cover of the fuel pipe clamp and remove the fuel pipe clamp from the fuel tube connector.

(2) Clamp Type B (Fuel Pipe Clamp):

Remove the fuel pipe clamp from the fuel tube connector.

(3) Check that there is no foreign matter around the fuel tube connector before disconnecting it. Clean it if necessary.

(4) While holding the retainer at the positions shown in the illustration, pull up the retainer to detach the lock claws.

*a	Retainer
	Retainer Holding Position
	Pull out

HINT:

If the lock claws of the retainer are difficult to detach, detach them using a screwdriver with its tip wrapped with protective tape.

*a	Retainer
*b	Protective Tape

(5) Pull up the retainer while holding it at the positions shown in the illustration and pull off the fuel tube connector.

*a	Retainer
*b	O-ring
*c	Fuel Tube Connector
*d	Nylon Tube
*e	Fuel Pipe
	Retainer Holding Position
	Pull out
	Pull off

(6) If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

NOTICE:

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).
Do not bend, twist, pinch or kink the nylon tube.

(7) Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

(8) Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

Perform the following procedure when connecting a fuel tube connector.

NOTICE:

Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

(1) Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, and then push in the retainer to secure the connection.

*a	Retainer
	Push
	Push in

NOTICE:

Confirm that the retainer makes a "click" sound when pushed.

HINT:

If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

(2) After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

(3) Clamp Type A (No. 1 Fuel Pipe Clamp):

Install the No. 1 fuel pipe clamp to the fuel tube connector and close the cover of the No. 1 fuel pipe clamp.

(4) Clamp Type B (Fuel Pipe Clamp):

Install the fuel pipe clamp to the fuel tube connector.

(5) Inspect for fuel leaks.

Click here

(d) Quick Type B:

Perform the following procedure when disconnecting a fuel tube connector.

NOTICE:

Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

(1) Detach the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

*a	Retainer
*b	Fuel Pipe
*c	Fuel Tube Connector
*d	O-ring
*e	Claw
	Push
	Pull out
	Pull off

NOTICE:

Be sure to disconnect the fuel tube connector by hand.

(2) If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

NOTICE:

Be sure to disconnect the fuel tube connector by hand.
Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the pipe (fuel pipe).

(3) Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

(4) Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

(e) Quick Type B:

Perform the following procedure when connecting a fuel tube connector.

NOTICE:

Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

(1) Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, and then push in the retainer to engage the 2 claws.

*a	Retainer
*b	Claw
	Push
	Push in

NOTICE:

Confirm that the retainer makes a "click" sound when pushed.

HINT:

If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

(2) After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

(3) Inspect for fuel leaks.

Click here

(f) Quick Type C:

Perform the following procedure when disconnecting a fuel tube connector.

NOTICE:

Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

(1) Push the claw of the retainer, push the retainer of fuel tube connector, and then pull the fuel tube connector off of the fuel tank assembly.

*a	Retainer
*b	O-ring
*c	Fuel Tube Connector
*d	Fuel Tank Assembly
*e	Claw
	Push
	Push
	Pull off

NOTICE:

Be sure to disconnect the fuel tube connector by hand.

(2) If the fuel tube connector and fuel tank assembly are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel tank assembly carefully.

NOTICE:

Be sure to disconnect the fuel tube connector by hand.
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 tank assembly).

(3) Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

(4) Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

(g) Quick Type C:

Perform the following procedure when connecting a fuel tube connector.

NOTICE:

Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

(1) Pull out the retainer until the retainer makes a "click" sound.

*a	Retainer
	Pull out

(2) Align the fuel tube connector with the fuel tank assembly, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean gasoline to the tip of the fuel pipe and reinsert it.

*a	Retainer
	Push
	Push in

(3) Connect the fuel lines and push in the retainer. Check that the fuel tube connector is securely connected by pulling on it.

(4) Inspect for fuel leaks.

Click here

(h) Observe the following precautions when handling a nylon tube:

NOTICE:

Do not twist the nylon tube of the fuel tube connector or fuel tube connector when connecting it.
Do not remove the Ethylene Propylene Diene Monomer (EPDM) rubber protector on the outside of the nylon tube.
Do not bend, twist, pinch or kink the nylon tube.

*a	Fuel Tube Connector
*b	Nylon Tube
*c	Ethylene Propylene Diene Monomer (EPDM) Rubber Protector

FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

NOTICE:

Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube with pump and gauge assembly. Doing so will cause reassembly of the fuel suction tube with pump and gauge assembly to be impossible as the tube is pressed into the fuel suction plate sub-assembly.

*A	w/ Canister Pump Module
*B	w/o Canister Pump Module
*a	Tube

When replacing the fuel filter, replace it together with the fuel sub-tank sub-assembly.

INSPECT FOR FUEL LEAK

(a) Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs.

Click here