Fuel Tank Removal

Engine. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
2Az-Fe Fuel. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. DISCHARGE FUEL SYSTEM PRESSURE

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE FUEL TANK CAP

  4. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY

  5. REMOVE NO. 1 FUEL TANK PROTECTOR

  6. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

  7. REMOVE FUEL HOSE PROTECTOR

  8. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

  9. DISCONNECT FUEL TANK BREATHER HOSE

  10. DISCONNECT AIR INLET LINE HOSE

  11. REMOVE FUEL TANK FILLER PIPE

  12. REMOVE FUEL TANK ASSEMBLY

Fuel Tank -- Removal



1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
  1. DISCHARGE FUEL SYSTEM PRESSURE procedures must be performed before disconnecting any part of the fuel system.
  2. 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.

  1. Remove the console box (RAV4_ACA30 RM000001RHJ00GX_01_0039.html).



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.2Az-Fe Fuel.Fuel System.Fuel Tank Removal

  1. Disconnect the connector.

  1. Start the engine. After the engine has stopped, turn the ignition switch off.

    HINT:
    DTC P0171 (system too lean) may be set.

  1. Check that the engine does not start.

  1. Remove the fuel tank cap, and let the air out of the fuel tank.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.2Az-Fe Fuel.Fuel System.Fuel Tank Removal

  1. Connect the connector.

  1. Install the console box (RAV4_ACA30 RM000001RHG00HX_01_0010.html).



2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.


3. REMOVE FUEL TANK CAP


4. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 2 bolts and disconnect the parking brake cable.



5. REMOVE NO. 1 FUEL TANK PROTECTOR

  1. Remove the 2 clips and grommet.

  1. Remove the 2 bolts and fuel tank protector.



6. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.2Az-Fe Fuel.Fuel System.Fuel Tank Removal

  1. Pinch and pull the main tube connector to disconnect the connector from the pipe.

    NOTICE:
    1. Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
    2. Do not use any tools to separate the pipe and connector.
    3. Do not forcefully bend or twist the nylon tube.
    4. Check for foreign matter on the pipe seal surface. Clean if necessary.
    5. Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
    6. If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.

  1. Disconnect the purge line hose from the pipe.



7. REMOVE FUEL HOSE PROTECTOR


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Detach the claw and remove the fuel hose protector from the filler pipe hose.



8. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Disconnect the filler pipe hose from the fuel tank.



9. DISCONNECT FUEL TANK BREATHER HOSE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Disconnect the breather hose from the fuel tank.



10. DISCONNECT AIR INLET LINE HOSE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the air inlet line hose.



11. REMOVE FUEL TANK FILLER PIPE

  1. Remove the 3 bolts and filler pipe protector.

  1. Remove the 2 bolts and filler pipe.



12. REMOVE FUEL TANK ASSEMBLY

  1. Set a transmission jack underneath the fuel tank.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 6 bolts and 3 fuel tank bands.

  1. Slightly lower the transmission jack.

    NOTICE:
    Be careful not to cut the wiring.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.2Az-Fe Fuel.Fuel System.Fuel Tank Removal

  1. Fold back approximately half of any cushion rubber necessary for the detachment of the wire harness from the fuel tank in the step below.

  1. Disconnect the fuel pump connector and sender gauge connector.

    NOTICE:
    1. Before this procedure, check the connector for dirt, mud or other contamination.
    2. Do not use any tools in this procedure.

  1. Detach the wire harness from the 4 clamps and remove the fuel tank.