Toyota RAV4 > Fuel and exhaust systems > Fuel pump module/fuel level sending unit — removal and installation

Fuel pump module/fuel level sending unit — removal and installation

Warning: Gasoline is extremely flammable, so take extra precautions when you work on any part of the fuel system. See Fuel system warnings in Fuel and exhaust systems.

Note: All models are equipped with a separate fuel level sending unit located in the front half of the tank.

Removal

1. Relieve the fuel system pressure (see Fuel pressure relief procedure) and remove the fuel tank cap.

2. Disconnect the cable from the negative battery terminal (see Engine electrical systems).

3. Remove the fuel tank (see Fuel tank — removal and installation).

4. Clean the top of the fuel tank, fuel pump module and fuel sending unit to prevent contaminants from getting into the tank once the module is removed.

Fuel pump module

5. Remove the clip and disconnect the fuel supply line and connector at the fuel pump module (see illustration).

6. Remove the eight-fuel pump module retaining bolts.

7. Carefully withdraw the fuel pump module assembly from the fuel tank, free the clamp and disconnect the fuel sub-suction hose (see illustration).

i. 7 Disconnect the fuel sub-suction hose

Toyota RAV4 Fuel and exhaust systems | Fuel pump module/fuel level sending unit - removal and installation _ Disconnect the fuel sub-suction hose

8. Remove the fuel pump module from the tank and drain the fuel into a suitable container.

Fuel pump and fuel filter

9. Disconnect the electrical connector from the fuel pump main body (see illustration).

i. 9 Disconnect the fuel pump connector from the main body

Toyota RAV4 Fuel and exhaust systems | Fuel pump module/fuel level sending unit - removal and installation _ Disconnect the fuel pump connector from the main body

10. Remove the clips(s) from the sliders. Pull the top of the module away from the sub-tanks and remove the springs from the sliders (see illustration).

i. 10 Remove the clips using needle-nosed pliers

Toyota RAV4 Fuel and exhaust systems | Fuel pump module/fuel level sending unit - removal and installation _ Remove the clips using needle-nosed pliers

11. Pry away the two tabs at the top of sub-tank 1 and 2 and remove the sub-tank 1 from sub-tank 2 (see illustrations).

i. 11a Disengage the retaining tabs.

Toyota RAV4 Fuel and exhaust systems | Fuel pump module/fuel level sending unit - removal and installation _ Disengage the retaining tabs

i. 11b… and separate the sub-tank 1 from sub-tank 2

Toyota RAV4 Fuel and exhaust systems | Fuel pump module/fuel level sending unit - removal and installation _ separate the sub-tank 1 from sub-tank 2

12. Pry back the retainer and remove the jet pump module at the bottom of sub-tank 2 (see illustration).

i. 12 Remove the jet pump module

Toyota RAV4 Fuel and exhaust systems | Fuel pump module/fuel level sending unit - removal and installation _ Remove the jet pump module

13. Use a tape-wrapped tip screwdriver to remove the jet pump from the top of sub-tank 2.

Note: Replace the 0-ring on the jet pump.

14. Carefully pry the five tabs from the bottom of sub-tank 1 and pull the fuel pump out of sub-tank 1 (see illustration).

i. 14 Remove the fuel pump from sub-tank 1

Toyota RAV4 Fuel and exhaust systems | Fuel pump module/fuel level sending unit - removal and installation _ Remove the fuel pump from sub-tank 1

Note: Sub-tank 1 is also the fuel filter.

15. Disconnect the fuel pump electrical connector and remove the fuel pump.

Note: Replace the 0-ring on the fuel pump.

Fuel level sending unit

16. Remove the five screws and remove fuel level sending unit assembly from the fuel tank (see illustration).

i. 16 Fuel level sending unit

Toyota RAV4 Fuel and exhaust systems | Fuel pump module/fuel level sending unit - removal and installation _ Fuel level sending unit

17. Carefully angle the sending unit out of the opening without damaging the fuel level float located at the bottom of the assembly.

Installation

18. Reassemble the fuel pump module in the reverse order of disassembly.

19. Install the fuel pump/sending unit assemblies in the fuel tank.

20. The remainder of installation is the reverse of removal.

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