Toyota RAV4 2000-05

Fuel Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Loosen the fuel cap to relieve any fuel pressure within the tank.



    Negative battery cable
     
    Left-hand rear seat assembly
     
    Floor service hole by pulling back the carpet; then, remove the 4 screws
     
    Fuel pump and sender gauge connector
     



    Fuel pipe union bolt and both gaskets
     
    Fuel pump outlet pipe
     
    Return vent hose from the fuel pump
     
    8 fuel pump bolts and the pump assembly from the tank
     

  6.  

To install:

  1. Install or connect the following:

    Fuel pump to the fuel tank. Tighten the 8 bolts to 31 inch lbs. (3.5 Nm).
     
    Return vent hose to the fuel pump
     
    Outlet pipe to the fuel pump, using new gaskets. Tighten the union bolts to 22 ft. lbs. (29 Nm).
     
    Fuel pump and sender gauge connector
     
    Floor hole cover with the 4 screws
     
    Carpet
     
    Left rear seat assembly
     
    Negative battery cable
     
    Fuel cap
     

  2.  
  3. Start the vehicle and check for leaks.
  4.  

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Left-hand rear seat assembly
     
    Floor service hole by pulling back the carpet; then, remove the 4 screws
     
    Fuel pump and sender gauge connector
     

  6.  


NOTE
Loosen the fuel cap to relieve any fuel pressure within the tank.



Fuel pipe union bolt and both gaskets
 
Fuel pump outlet pipe
 
Return vent hose from the fuel pump
 
8 fuel pump bolts and the pump assembly from the tank
 

To install:

  1. Install or connect the following:

    Fuel pump to the fuel tank. Tighten the 8 bolts to 31 inch lbs. (3.5 Nm).
     
    Return vent hose to the fuel pump
     
    Outlet pipe to the fuel pump, using new gaskets. Tighten the union bolts to 22 ft. lbs. (29 Nm).
     
    Fuel pump and sender gauge connector
     
    Floor hole cover with the 4 screws
     
    Carpet
     
    Left rear seat assembly
     
    Negative battery cable
     
    Fuel cap
     

  2.  
  3. Start the vehicle and check for leaks.
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Loosen the fuel cap to relieve any fuel pressure within the tank.



    Negative battery cable
     
    Left side rear seat assembly
     
    Floor service hole by pulling back the carpet; then, remove the 4 screws
     
    Fuel pump and sender gauge connector
     



    Fuel pipe union bolt and both gaskets
     
    Fuel pump outlet pipe
     
    Return vent hose from the fuel pump
     
    8 fuel pump bolts and the pump assembly from the tank
     

  6.  

To install:

  1. Install or connect the following:

    Fuel pump to the fuel tank. Tighten the 8 bolts to 31 inch lbs. (3.5 Nm).
     
    Return vent hose to the fuel pump
     
    Outlet pipe to the fuel pump, using new gaskets. Tighten the union bolts to 22 ft. lbs. (29 Nm).
     
    Fuel pump and sender gauge connector
     
    Floor hole cover with the 4 screws
     
    Carpet
     
    Left rear seat assembly
     
    Negative battery cable
     
    Fuel cap
     

  2.  
  3. Start the vehicle and check for leaks.
  4.  

2.4L Engine


Click image to see an enlarged view

Fig. Fuel pump module-2.4L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Left-hand rear seat assembly
     
    Floor service hole by pulling back the carpet; then, remove the 4 screws
     
    Fuel pump and sender gauge connector
     

  6.  


NOTE
Loosen the fuel cap to relieve any fuel pressure within the tank.



Fuel pipe
 
Fuel pump outlet pipe
 
Return vent hose from the fuel pump
 
8 fuel pump bolts and the pump assembly from the tank
 

To install:

  1. Install or connect the following:

    Fuel pump to the fuel tank. Position the unit as shown. Tighten the 8 bolts to 35 inch lbs. (4 Nm).
     


    Click image to see an enlarged view

    Fig. Proper fuel pump installation-2.4L engine

    Return vent hose to the fuel pump
     
    Fuel pump and sender gauge connector
     
    Floor hole cover with the 4 screws
     
    Carpet
     
    Left rear seat assembly
     
    Negative battery cable
     
    Fuel cap
     

  2.  
  3. Start the vehicle and check for leaks.
  4.  



Click image to see an enlarged view

Fig. Fuel pump and related components-2.4L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Loosen the fuel cap to relieve any fuel pressure within the tank.



    Negative battery cable
     
    Left side rear seat assembly
     
    Floor service hole by pulling back the carpet; then, remove the 4 screws
     
    Fuel pump and sender gauge connector
     



    Fuel pipe
     
    Fuel pump outlet pipe
     
    Return vent hose from the fuel pump
     
    8 fuel pump bolts and the pump assembly from the tank
     

  6.  

To install:

  1. Install or connect the following:

    Fuel pump to the fuel tank. Position the unit as shown. Tighten the 8 bolts to 35 inch lbs. (4 Nm).

    Click image to see an enlarged view

    Fig. Proper fuel pump installation-2.4L engine

     
    Return vent hose to the fuel pump
     
    Fuel pump and sender gauge connector
     
    Floor hole cover with the 4 screws
     
    Carpet
     
    Left rear seat assembly
     
    Negative battery cable
     
    Fuel cap
     

  2.  
  3. Start the vehicle and check for leaks.
  4.  

 
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