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

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

*: When performing learning using the Techstream.

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; PARK ASSIST / MONITORING: PARKING SUPPORT BRAKE SYSTEM (for HV Model): CALIBRATION

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane control system

2022 - 2024 MY RAV4 RAV4 HV [12/2021 -        ]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Parking support brake system*

Pre-collision system

Reset back door close position

Power back door system

2019 - 2023 MY RAV4 HV [11/2018 - 10/2023]; DOOR / HATCH: POWER BACK DOOR SYSTEM (for HV Model): INITIALIZATION

Back door lock initialization

Power door lock control system

2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DOOR LOCK: POWER DOOR LOCK CONTROL 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.
  • 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

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 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

2. DISCHARGE FUEL SYSTEM PRESSURE

Click here 2021 - 2024 MY RAV4 HV [08/2020 -        ]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

3. REMOVE DECK BOARD ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+

4. REMOVE REAR NO. 2 FLOOR BOARD

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+

5. REMOVE BATTERY HOLE COVER

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL+

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 2023 MY RAV4 RAV4 HV [10/2022 - 10/2023]; INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION

7. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (FUEL): FUEL PUMP (w/ Canister Pump Module): REMOVAL

8. DRAIN FUEL

9. REMOVE FRONT FENDER FRONT SPLASH SHIELD LH

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

10. REMOVE FRONT FENDER FRONT SPLASH SHIELD RH

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

11. REMOVE NO. 1 ENGINE UNDER COVER

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

12. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

13. REMOVE FRONT FLOOR COVER LH

(a) Detach the clip and remove the 2 bolts and 4 screws.

(b) Loosen the 7 nuts and remove the front floor cover LH from the body.

14. REMOVE FRONT CENTER FLOOR COVER

(a) Detach the 2 clips and remove the front center floor cover from the body.

15. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY

(a) Disconnect the fuel tank vent hose sub-assembly from the fuel tank solenoid main valve assembly.

Click here 2021 - 2024 MY RAV4 HV [08/2020 -        ]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

16. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Disconnect the fuel tank main tube sub-assembly from the fuel tube.

Click here 2021 - 2024 MY RAV4 HV [08/2020 -        ]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

17. DISCONNECT FUEL TANK BREATHER TUBE

(a) Disconnect the fuel tank breather tube from the fuel tank filler pipe assembly.

Click here 2021 - 2024 MY RAV4 HV [08/2020 -        ]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

18. DISCONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY

(a) Disconnect the fuel tank filler pipe sub-assembly from the fuel tank filler pipe assembly.

Click here 2021 - 2024 MY RAV4 HV [08/2020 -        ]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

19. DISCONNECT FRONT LOWER NO. 1 FLOOR HEAT INSULATOR

(a) Detach the clip and disconnect the front lower No. 1 floor heat insulator from the fuel tank band sub-assembly.

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.

(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.

(b) Remove the 4 bolts, fuel tank band and fuel tank band LH.

(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

(a) Detach the clamp and remove the fuel tank main tube sub-assembly from the fuel tank assembly.

22. REMOVE FUEL TANK VENT HOSE SUB-ASSEMBLY

(a) Disconnect the fuel tank vent hose sub-assembly from the fuel tank evaporation tube sub-assembly.

Click here 2021 - 2024 MY RAV4 HV [08/2020 -        ]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

(b) Detach the 2 clamps and remove the fuel tank vent hose sub-assembly from the fuel tank assembly.

23. REMOVE NO. 2 FUEL TANK PROTECTOR

(a) Detach the 2 claws and remove the No. 2 fuel tank protector from the fuel tank protector sub-assembly.

24. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

(a) Detach the 2 claws and remove the No. 1 fuel tank protector sub-assembly from the fuel tank assembly.

25. REMOVE NO. 6 FUEL TANK CUSHION

(a) Remove the 5 No. 6 fuel tank cushions from the fuel tank assembly.