| Last Modified: 01-30-2024 | 6.11:8.1.0 | Doc ID: RM1000000026X2N |
| Model Year Start: 2023 | Model: RAV4 HV | Prod Date Range: [10/2022 - 10/2023] |
| Title: A25A-FXS (FUEL): FUEL TANK (w/ Canister Pump Module): REMOVAL; 2023 MY RAV4 HV [10/2022 - 10/2023] | ||
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 tank assembly removal/installation are shown below.
Necessary Procedures After Parts Removed/Installed/Replaced
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Replaced Part or Performed Procedure |
Necessary Procedure |
Effect/Inoperative Function when Necessary Procedure not Performed |
Link |
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*: When performing learning using the Techstream.
Click here
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Auxiliary battery terminal is disconnected/reconnected |
Perform steering sensor zero point calibration |
Lane control system |
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Parking support brake system* |
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Pre-collision system |
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Reset back door close position |
Power back door system |
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Back door lock initialization |
Power door lock control system |
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CAUTION:
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Never perform work on fuel system components near any possible ignition sources.
- Vaporized fuel could ignite, resulting in a serious accident.
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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.
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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.
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.
Click here
![2021 - 2024 MY RAV4 HV [08/2020 - ]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION](/t3Portal/stylegraphics/info.gif)
PROCEDURE
1. PRECAUTION
NOTICE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.
Click here
2. DISCHARGE FUEL SYSTEM PRESSURE
Click here
3. REMOVE DECK BOARD ASSEMBLY
Click here
4. REMOVE REAR NO. 2 FLOOR BOARD
Click here
5. REMOVE BATTERY HOLE COVER
Click here
6. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
Click here
7. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
Click here
8. DRAIN FUEL
9. REMOVE FRONT FENDER FRONT SPLASH SHIELD LH
Click here
10. REMOVE FRONT FENDER FRONT SPLASH SHIELD RH
Click here
11. REMOVE NO. 1 ENGINE UNDER COVER
Click here
12. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY
Click here
13. REMOVE FRONT FLOOR COVER LH
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(a) Detach the clip and remove the 2 bolts and 4 screws. |
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(b) Loosen the 7 nuts and remove the front floor cover LH from the body. |
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14. REMOVE FRONT CENTER FLOOR COVER
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(a) Detach the 2 clips and remove the front center floor cover from the body. |
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15. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY
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(a) Disconnect the fuel tank vent hose sub-assembly from the fuel tank solenoid main valve assembly. Click here
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16. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
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(a) Disconnect the fuel tank main tube sub-assembly from the fuel tube. Click here
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17. DISCONNECT FUEL TANK BREATHER TUBE
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(a) Disconnect the fuel tank breather tube from the fuel tank filler pipe assembly. Click here
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18. DISCONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY
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(a) Disconnect the fuel tank filler pipe sub-assembly from the fuel tank filler pipe assembly. Click here
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19. DISCONNECT FRONT LOWER NO. 1 FLOOR HEAT INSULATOR
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(a) Detach the clip and disconnect the front lower No. 1 floor heat insulator from the fuel tank band sub-assembly. |
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20. REMOVE 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.
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(a) Using an engine lifter, support the fuel tank assembly. HINT: Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal. |
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(b) Remove the 4 bolts, fuel tank band and fuel tank band LH. |
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(c) Lower the engine lifter and remove the fuel tank assembly.
NOTICE:
- Be careful not to drop the fuel tank assembly.
- When removing the fuel tank assembly, tilt it slightly to prevent it from interfering with the surrounding parts.
21. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
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(a) Detach the clamp and remove the fuel tank main tube sub-assembly from the fuel tank assembly. |
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22. REMOVE FUEL TANK VENT HOSE SUB-ASSEMBLY
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(a) Disconnect the fuel tank vent hose sub-assembly from the fuel tank evaporation tube sub-assembly. Click here
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(b) Detach the 2 clamps and remove the fuel tank vent hose sub-assembly from the fuel tank assembly. |
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23. REMOVE NO. 2 FUEL TANK PROTECTOR
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(a) Detach the 2 claws and remove the No. 2 fuel tank protector from the fuel tank protector sub-assembly. |
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24. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
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(a) Detach the 2 claws and remove the No. 1 fuel tank protector sub-assembly from the fuel tank assembly. |
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25. REMOVE NO. 6 FUEL TANK CUSHION
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(a) Remove the 5 No. 6 fuel tank cushions from the fuel tank assembly. |
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