fuel tank removal TOYOTA RAV4 2006 Service Repair Manual

2AZ-FE FUEL – FUEL INJECTORFU–9
FU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
• DISCHARGE FUEL SYSTEM PRESSURE
procedures must be performed before
disconnecting any part of the fuel system.
• After performing the DISCHARGE FUEL SYSTEM
PRESSURE procedures, pressure will remain in
the fuel line. When disconnecting the fuel line,
place a cloth or equivalent over fittings to reduce
the risk of fuel spray.
(a) Remove the console box (see page IR-83).
(b) Disconnect the connector.
(c) Start the engine. After the engine has stopped, turn
the ignition switch off.
HINT:
DTC P0171 (system too lean) may be set.
(d) Check that the engine does not start.
(e) Remove the fuel tank cap, and let the air out of the
fuel tank.
(f) Connect the connector.
(g) Install the console box (see page IR-90).
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 NO. 1 ENGINE COVER (See page ES-410)
4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page ES-411)
A128750E01
A128750E01

2AZ-FE FUEL – FUEL PRESSURE REGULATORFU–17
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.
A125344
A125345
A125346

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.
A125344
A125345
A125346

FU–402AZ-FE FUEL – FUEL TANK
FU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See page
FU-9)
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.
A124659
A131635

2GR-FE FUEL – FUEL INJECTORFU–13
FU
REMOVAL
CAUTION:
Do not allow fuel to spray when removing the pipe
between the high pressure side fuel pump and the fuel
injector. The fuel in the pipe is highly pressurized.
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
• The "DISCHARGE FUEL SYSTEM PRESSURE"
procedures must be performed before
disconnecting any part of the fuel system.
• After performing the "DISCHARGE FUEL SYSTEM
PRESSURE" procedures, pressure will remain in
the fuel line. When disconnecting the fuel line,
place a cloth or equivalent over fittings to reduce
the risk of fuel spray.
(a) Remove the console box (see page IP-16).
(b) Start the engine. After the engine has stopped, turn
the ignition switch OFF.
HINT:
DTC P0171/P0172 (system too lean) may be set.
(c) Check that the engine does not start.
(d) Remove the fuel tank cap, and let the air out of the
fuel tank.
(e) Connect the connector.
(f) Install the console box (see page IP-23).
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 ENGINE ASSEMBLY
(a) Remove the engine (see page EM-21).
4. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
(See page EM-27)
5. DISCONNECT FUEL MAIN TUBE
(a) Remove the No. 2 fuel pipe clamp.
A128750E01
A128750E01
A134142E01

FU–222GR-FE FUEL – FUEL PUMP
FU
REMOVAL
1. REMOVE FUEL TANK ASSEMBLY
(a) Remove the fuel tank (see page FU-33).
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.
A125344
A125345
A125346

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.
A124659
A131635