TOYOTA RAV4 2006 Service Repair Manual

2GR-FE FUEL – FUEL PUMPFU–23
FU
(b) Remove the gasket from the fuel pump.
5. REMOVE FUEL SUB-TANK ASSEMBLY
(a) Disconnect the wire harness.
(b) Using needle nose pliers, remove the E-ring.
HINT:
Slightly lower the sub-tank to remove the E-ring.
(c) Remove the 2 springs from the 2 shafts.
(d) Detach the 2 claws and remove the sub-tank.
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FU–242GR-FE FUEL – FUEL PUMP
FU
(e) Detach the claw of the jet pump nozzle and remove
the jet pump nozzle.
(f) Using a screwdriver, remove the jet pump.
HINT:
Tape the screwdriver tip before use.
(g) Remove the O-ring from the jet pump.
6. REMOVE BRACKET
(a) Using a screwdriver, detach the 2 claws and remove
the bracket.
HINT:
Tape the screwdriver tip before use.
7. REMOVE FUEL PUMP ASSEMBLY
(a) Detach the 5 claws on the filter and remove the fuel
pump from the fuel filter.
HINT:
When removing the claw, do not disconnect the fuel
main tube.
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2GR-FE FUEL – FUEL PUMPFU–25
FU
(b) Disconnect the fuel pump connector.
(c) Remove the O-ring from the fuel filter.
INSPECTION
1. INSPECT FUEL PUMP
(a) Check the fuel pump resistance.
(1) Measure the resistance between terminals 1
and 2.
Standard resistance:
0.2 to 3.0
at 20C (68F)
If the result is not as specified, replace the fuel
pump.
(b) Check fuel pump operation.
(1) Apply battery voltage to terminals 1 and 2.
Check that the pump operates.
NOTICE:
• These tests must be completed within 10
seconds to prevent the coil from burning
out.
• Keep the fuel pump as far away from the
battery as possible.
• Always turn the voltage on and off on the
battery side, not the fuel pump side.
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FU–262GR-FE FUEL – FUEL PUMP
FU
If the pump does not operate, replace the fuel
pump.
INSTALLATION
1. INSTALL FUEL PUMP ASSEMBLY
(a) Connect the pump harness connector.
(b) Apply gasoline to a new O-ring and install the O-ring
to the fuel filter.
(c) Attach the 5 claws to the claw holes and install the
fuel pump.
2. INSTALL BRACKET
(a) Attach the 2 claws to the claw holes and install the
bracket.
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2GR-FE FUEL – FUEL PUMPFU–27
FU
3. INSTALL FUEL SUB-TANK ASSEMBLY
(a) Apply gasoline to a new O-ring and install it to the
jet pump.
(b) Install the jet pump while aligning it with the
installation position of the sub-tank.
(c) Install the jet pump nozzle.
(d) Attach the 2 claws to the claw holes and install the
fuel sub-tank.
(e) Connect the wire harness.
(f) Install the springs to the fuel suction plate shafts and
install them to the sub-tank.
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FU–282GR-FE FUEL – FUEL PUMP
FU
(g) Using needle-nose pliers, install a new E-ring.
HINT:
Slightly lower the sub-tank to install the E-ring.
4. INSTALL FUEL SUCTION WITH PUMP ASSEMBLY
(a) Install a new gasket onto the fuel pump.
(b) Connect the fuel hose and install the fuel pump into
the fuel tank.
NOTICE:
Do not damage the fuel pump filter.
5. INSTALL FUEL TANK VENT TUBE SET PLATE
(a) Install the set plate with the 8 bolts.
Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
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2GR-FE FUEL – FUEL PUMPFU–29
FU
6. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Install the fuel tank main tube with the joint clip.
CAUTION:
• Check that there are no scratches or foreign
objects on the connecting parts.
• Check that the fuel tube joint is inserted
securely.
• Check that the fuel tube joint clip is on the
collars of the fuel tube joint.
• After installing the tube joint clip, check that
the fuel tube joint has not been pulled off.
• Be careful not to damage the clip. If the clip is
damaged, replace it.
7. INSTALL FUEL TANK ASSEMBLY
(a) Install the fuel tank (see page FU-38).
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FU–342GR-FE FUEL – FUEL TANK
FU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See page
FU-13)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
3. REMOVE FUEL TANK CAP
4. REMOVE FRONT FLOOR COVER
(a) Remove the nut, bolt, 3 clips and floor cover.
5. REMOVE NO. 1 FLOOR UNDER COVER
(a) Remove the 2 nuts, clip and floor under cover.
6. DISCONNECT NO. 2 PARKING BRAKE CABLE
ASSEMBLY
(a) Remove the 2 bolts and disconnect the parking
brake cable.
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2GR-FE FUEL – FUEL TANKFU–35
FU
7. DISCONNECT FUEL TANK MAIN TUBE SUB-
ASSEMBLY
(a) Pinch and pull the main tube connector to
disconnect the connector from the pipe.
NOTICE:
• Check for foreign matter in the pipe and
around the connector. Clean if necessary.
Foreign matter may damage the O-ring or
cause leaks in the seal between the pipe and
connector.
• Do not use any tools to separate the pipe and
connector.
• Do not forcefully bend or twist the nylon tube.
• Check for foreign matter on the pipe seal
surface. Clean if necessary.
• Put the pipe and connector ends in plastic
bags to prevent damage and foreign matter
contamination.
• If the pipe and connector are stuck together,
pinch the connector between your fingers
and turn it carefully to disconnect it.
(b) Disconnect the EVAP hose from the tank.
8. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
(a) Disconnect the filler pipe hose from the fuel tank.
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FU–362GR-FE FUEL – FUEL TANK
FU
9. DISCONNECT FUEL TANK BREATHER HOSE
(a) Disconnect the breather hose from the fuel tank.
NOTICE:
• Check for foreign matter in the pipe and
around the connector. Clean if necessary.
Foreign matter may damage the O-ring or
cause leaks in the seal between the pipe and
connector.
• Do not use any tools to separate the pipe and
connector.
• Do not forcefully bend or twist the nylon tube.
• Check for foreign matter on the pipe seal
surface. Clean if necessary.
• Put the pipe and connector ends in plastic
bags to prevent damage and foreign matter
contamination.
• If the pipe and connector are stuck together,
pinch the connector between your fingers
and turn it carefully to disconnect it.
10. REMOVE FUEL TANK FILLER PIPE
(a) Remove the 3 bolts and filler pipe protector.
(b) Remove the 2 bolts and filler pipe.
11. REMOVE FUEL TANK ASSEMBLY
(a) Set a mission jack underneath the fuel tank.
(b) Remove the 6 bolts and 3 fuel tank bands.
(c) Slightly lower the mission jack.
NOTICE:
Be careful not to cut the wirings.
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