Toyota RAV4 > Fuel and exhaust systems > Fuel tank — removal and installation

Fuel tank — 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 Section Fuel and exhaust systems.

1. Relieve the fuel system pressure (see Fuel pressure relief procedure).

2. Remove the fuel filler cap to relieve fuel tank pressure.

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

4. If the tank is full or nearly full, siphon the fuel into an approved container using a siphoning kit (available at most auto parts stores).

Warning: Do not start the siphoning action by mouth!

5. Raise the vehicle and support it securely on jack stands.

Warning: To avoid personal injury, never get beneath the vehicle when it is supported only by a jack. The jack provided with your vehicle is designed solely for raising the vehicle to remove and replace the wheels. Always use jack stands to support the vehicle when it becomes necessary to place your body underneath the vehicle.

6. Disconnect the two parking brake cable brackets from around the tank and position to the side (see illustration).

i. 6 Remove the bolts and position the parking brake cable brackets out of the way

Toyota RAV4 Fuel and exhaust systems | Fuel tank - removal and installation _ Remove the bolts and position the parking brake cable brackets out of the way

7. Remove the two nuts/bolts and multiple clips to remove the front underfloor cover (see illustration).

i. 7 Identifying the floor undercover

Toyota RAV4 Fuel and exhaust systems | Fuel tank - removal and installation _ Identifying the floor undercover

8. Remove the one nut and three clips and remove the front fuel tank shield (see illustration).

i. 8 Identifying the front fuel tank shield

Toyota RAV4 Fuel and exhaust systems | Fuel tank - removal and installation _ Identifying the front fuel tank shield

9. Remove the two nuts and remove the rear underfloor cover near the tank and rear trailing arm (see illustration).

i. 9 Identifying the rear underfloor cover

Toyota RAV4 Fuel and exhaust systems | Fuel tank - removal and installation _ Identifying the rear underfloor cover

10. Disconnect the fuel line, vapor return.

line, and EVAP hose (see Fuel lines and fittings – general information and disconnection for fitting disconnection details) (see illustration).

i.10 Disconnect the fuel line (A), EVAP hose (B) and vapor return line

Toyota RAV4 Fuel and exhaust systems | Fuel tank - removal and installation _ Disconnect the fuel line (A), EVAP hose (B) and vapor return line

Note: Be sure to plug the hoses to prevent leakage and contamination of the fuel system.

11. Remove the fuel filler tube shield by disengaging the claw at the top of the shield (see illustration).

i.11 Remove the filler tube shield by disengaging the claw

Toyota RAV4 Fuel and exhaust systems | Fuel tank - removal and installation _ Remove the filler tube shield by disengaging the claw

12. Loosen the clamps but disconnect only the fuel tank-to-filler pipe hose from the fuel tank (see illustration).

i.12 Loosen both clamps but only disconnect the filler hose at the tank

Toyota RAV4 Fuel and exhaust systems | Fuel tank - removal and installation _ Loosen both clamps but only disconnect the filler hose at the tank

13. Detach the wiring harness clips from the three tabs on the side of the fuel tank.

14. Support the fuel tank with a floor jack. Place a sturdy plank between the jack head and the fuel tank to protect the tank (see illustration).

i. 14 Support the fuel tank

Toyota RAV4 Fuel and exhaust systems | Fuel tank - removal and installation _ Support the fuel tank

15. Remove the bolts from the fuel tank retaining straps (see illustration).

i. 15 Remove the fuel tank strap mounting bolts from the body

Toyota RAV4 Fuel and exhaust systems | Fuel tank - removal and installation _ Remove the fuel tank strap mounting bolts from the body

16. Slowly lower the tank enough to fold back the fuel tank cushion and remove the wiring harness from the retainer in the fuel tank.

17. Disconnect the two electrical connectors from the fuel pump module and fuel gauge sending unit (see illustrations).

i. 17a Disconnect the fuel pump module connector.

Toyota RAV4 Fuel and exhaust systems | Fuel tank - removal and installation _ Disconnect the fuel pump module connector

i. 17b… and the fuel sending unit connector

Toyota RAV4 Fuel and exhaust systems | Fuel tank - removal and installation _ the fuel sending unit connector

Note: It may be necessary to pull the harness through the grommet and disconnect it from inside the vehicle.

18. Remove the tank from the vehicle.

19. Remove or replace the fuel pump module and/or sending unit as necessary (see Fuel pump module/fuel level sending unit — removal and installation).

20. Clean any dirt or mud from the tank before installation.

21. Installation is the reverse of removal.

22. Use a scan tool to activate the fuel pump and check for leaks. If a scan tool is not available, turn the ignition to On and verify there are no fuel leaks. If no leaks are present, start and run the engine and check for leaks again.

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