fuel pump TOYOTA RAV4 2006 Service Service Manual

2AZ-FE FUEL – FUEL PUMPFU–31
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(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 shaft.
(d) Detach the 2 claws and remove the sub-tank.
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FU–322AZ-FE FUEL – FUEL PUMP
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(e) Disengage the claw of the jet pump nozzle.
(f) Using a screwdriver with the tip taped, remove the
jet pump.
(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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2AZ-FE FUEL – FUEL PUMPFU–33
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(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 the voltage on and off on the
battery side, not the fuel pump side.
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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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2AZ-FE FUEL – FUEL PUMPFU–35
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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 to 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 spring to the fuel suction plate shaft and
install them to the sub-tank.
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(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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2AZ-FE FUEL – FUEL PUMPFU–37
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6. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Install the fuel tube with the joint clips.
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-44).
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2AZ-FE FUEL – FUEL TANKFU–43
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(d) Fold back approximately half of each cushion
rubber so that the wire harness can be detached
from the fuel tank in the step below.
(e) Disconnect the fuel pump connector and sender
gauge connector.
NOTICE:
• Before this procedure, check the connector
for dirt, mud or other contamination.
• Do not use any tools in this procedure.
(f) Detach the wire harness from the 4 clamps and
remove the fuel tank.
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DISASSEMBLY
1. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
(See page FU-30)
2. REMOVE FUEL TANK VENT TUBE SET PLATE (See
page FU-30)
3. REMOVE FUEL SUCTION WITH PUMP ASSEMBLY
(See page FU-30)
4. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Remove the tube from the fuel tube clamps.
5. REMOVE NO. 1 FUEL TUBE CLAMP
(a) Remove the 4 tube clamps from the fuel tank.
6. REMOVE NO. 1 FUEL TANK CUSHION
(a) Remove the 7 fuel tank cushions from the fuel tank.
7. REMOVE FUEL SENDER GAUGE ASSEMBLY
(a) Remove the 5 screws and sender gauge.
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REASSEMBLY
1. INSTALL FUEL SENDER GAUGE ASSEMBLY
(a) Install the sender gauge with the 5 bolts.
Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf)
2. INSTALL NO. 1 FUEL TANK CUSHION
(a) Install 7 new fuel tank cushions onto the fuel tank as
shown in the illustration.
3. INSTALL NO. 1 FUEL TUBE CLAMP
(a) Install the 4 tube clamps to the fuel tank.
4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Install the tube with the 4 clips.
5. INSTALL FUEL SUCTION WITH PUMP ASSEMBLY
(See page FU-36)
6. INSTALL FUEL TANK VENT TUBE SET PLATE (See
page FU-36)
7. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
(See page FU-37)
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