TOYOTA RAV4 2006 Service Repair Manual

2AZ-FE FUEL – FUEL PRESSURE REGULATORFU–23
FU
(b) Connect the fuel hose and install the fuel pump into
the fuel tank.
NOTICE:
Do not damage the fuel pump filter.
6. 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)
7. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Install the fuel tube with the joint clips.
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FU–242AZ-FE FUEL – FUEL PRESSURE REGULATOR
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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.
8. INSTALL FUEL TANK ASSEMBLY
(a) Install the fuel tank (see page FU-44).
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2AZ-FE FUEL – FUEL PRESSURE PULSATION DAMPERFU–27
FU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See page
FU-9)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. REMOVE NO. 1 ENGINE COVER (See page ES-410)
4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-411)
5. DISCONNECT FUEL MAIN TUBE (See page FU-10)
6. REMOVE FUEL PRESSURE PULSATION DAMPER
ASSEMBLY
(a) Remove the 2 bolts and fuel pressure pulsation
damper.
INSTALLATION
1. INSTALL FUEL PRESSURE PULSATION DAMPER
ASSEMBLY
(a) Apply a light coat of gasoline or spindle oil to the O-
ring of the fuel pressure pulsation damper.
(b) Install the fuel pressure pulsation damper with the 2
bolts.
Torque: 9.0 N*m (90 kgf*cm, 80 in.*lbf)
NOTICE:
Make sure that the O-ring is not cracked or
jammed when installing.
2. INSTALL FUEL MAIN TUBE (See page FU-14)
3. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-413)
4. INSTALL NO. 1 ENGINE COVER (See page ES-414)
5. CONNECT CABLE TO BATTERY NEGATIVE
TERMINAL
6. CHECK FOR FUEL LEAKS (See page FU-14)
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FU–302AZ-FE FUEL – FUEL PUMP
FU
REMOVAL
1. REMOVE FUEL TANK ASSEMBLY
(a) Remove the fuel tank (see page FU-39).
2. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Remove the joint clip and fuel tank main tube.
CAUTION:
• Before removing the tube joint clip, check for
foreign matter around the clip. Clean if
necessary.
• Keep the O-ring free of foreign matter, as it
becomes contaminated easily.
• Do not use any tools in this procedure.
• Do not forcefully bend or twist the tube.
• Put the tube in a plastic bag to prevent
damage and contamination.
• If the fuel suction plate and tube are stuck
together, pinch the tube and turn it carefully
to disconnect it.
• Be careful not to damage the clip. If the clip is
damaged, replace it.
3. REMOVE FUEL TANK VENT TUBE SET PLATE
(a) Remove the 8 bolts and set plate.
4. REMOVE FUEL SUCTION WITH PUMP ASSEMBLY
(a) Disconnect the fuel hose and remove the fuel pump
from the fuel tank.
NOTICE:
Do not damage the fuel pump.
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2AZ-FE FUEL – FUEL PUMPFU–31
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 shaft.
(d) Detach the 2 claws and remove the sub-tank.
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FU–322AZ-FE FUEL – FUEL PUMP
FU
(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
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 the voltage on and off on the
battery side, not the fuel pump side.
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FU–342AZ-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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2AZ-FE FUEL – FUEL PUMPFU–35
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 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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FU–362AZ-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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