2005 Toyota RAV4 Base, FWD, AutomaticFACTORY OEM SERVICE PROCEDURE

Fuel Pump: Replacement

CAUTION: Do not smoke or work near an open flame when working on the fuel pump.
  1. REMOVE LH REAR SEAT 
  2. REMOVE FLOOR SERVICE HOLE COVER 
  3. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 
  4. DISCONNECT VAPOR PRESSURE SENSOR CONNECTOR 
  5. DISCONNECT FUEL TANK MAIN TUBE 
    CAUTION:
    • Disconnect the fuel tube connector (quick type) observing the precaution (see SFI SYSTEM ).
    • As there is retained pressure in the fuel line, prevent it from splashing inside the luggage compartment.

    Remove the tube joint clip and disconnect the main tube.

    Fig 1: Removing Tube Joint Clip & Disconnecting Main Tube
    G02639381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK 
    1. Remove the 8 bolts and fuel tank vent tube set plate.
      Fig 2: Removing Bolts & Fuel Tank Vent Tube Set Plate
      G02639382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Lift up the fuel pump and sender gauge assembly, and disconnect the fuel sub suction hose from the fuel return jet tube. Remove the fuel pump, sender gauge assembly and gasket.
      Fig 3: Disconnecting Fuel Sub Suction Hose From Fuel Return Jet Tube
      G02639383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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