A25A-FKS (FUEL): FUEL PUMP (for High Pressure): REMOVAL; 2024 - 2025 MY RAV4 [10/2023

Last Modified: 05-08-2025	6.11:8.1.0	Doc ID: RM100000002FR4I
Model Year Start: 2024	Model: RAV4	Prod Date Range: [10/2023 - ]
Title: A25A-FKS (FUEL): FUEL PUMP (for High Pressure): REMOVAL; 2024 - 2025 MY RAV4 [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 pump 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
1: When performing learning using the Techstream. 2: w/o Power Back Door System
Battery terminal is disconnected/reconnected	Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)	Stop and start system
	Perform steering sensor zero point calibration	Lane control system
		Parking support brake system*1
		Pre-collision system
	Reset back door close position	Power back door system
	Back door lock initialization*2	Power door lock control system
Replacement of fuel pump assembly Replacement of throttle body with motor assembly Cleaning the deposits from the throttle body with motor assembly Replacement of EGR valve assembly Gas leak from exhaust system is repaired	Inspection after repair	Poor idle, etc. Engine start function, etc.

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 (-) battery terminal.
Sparks could cause vaporized fuel to ignite, resulting in a serious accident.
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.

NOTICE:

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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2. DISCHARGE FUEL SYSTEM PRESSURE

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3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

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

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4. REMOVE INTAKE MANIFOLD

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5. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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

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6. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Disconnect the connector from the ignition coil assembly.

(b) Remove the bolt and disconnect the No. 1 fuel pipe sub-assembly from the cylinder head sub-assembly.

	Union Bolt
	Bolt

(d) Remove the bolt.

(e) Loosen the 2 bolts of the fuel pump assembly.

(f) Remove the No. 1 fuel pipe sub-assembly from the fuel delivery pipe and fuel pump assembly.

7. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY

NOTICE:

When replacing the fuel pump assembly, it is necessary to replace the No. 1 fuel pipe sub-assembly with a new one.

(a) Disconnect the connector from the fuel pump assembly.

(b) Remove the 2 bolts, fuel pump assembly and fuel pump flange from the cylinder head cover sub-assembly.

(d) Remove the fuel pump lifter assembly from the fuel pump lifter guide.

(e) Remove the fuel pump spacer gasket from the cylinder head cover sub-assembly.