This procedure covers the removal and replacement of the fuel filler cap on a 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine.

Warnings

Tools required

Parts

• Fuel filler cap × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and turn off engine
2. Allow fuel system to cool if vehicle was recently operated
3. Locate fuel filler door on left rear quarter panel

Procedure

1. 1

   Open fuel filler door
   Press the left rear edge of the fuel filler door to release the latch and open the door fully. The door is located on the driver's side rear quarter panel.
2. 2

   Remove old fuel cap
   Turn the fuel cap counterclockwise until it clicks and releases from the filler neck. Continue turning to fully remove the cap. Place the old cap aside if reusing or dispose of properly if replacing.
3. 3

   Inspect filler neck
   Visually inspect the fuel filler neck opening for any debris, damage, or corrosion. Wipe clean with a lint-free cloth if necessary. Check the rubber seal inside the filler neck for cracks or deterioration.
4. 4

   Install new fuel cap
   Align the new fuel cap with the filler neck and insert fully. Turn clockwise until you hear at least three distinct clicks. This ensures proper sealing and prevents evaporative emission leaks.
5. 5

   Close fuel filler door
   Push the fuel filler door closed until it latches securely. Verify it sits flush with the body panel.

Reassembly

1. No reassembly required for this procedure

Verification

• Verify the fuel cap clicks at least three times when tightened to confirm proper installation
• Confirm fuel filler door closes and latches properly
• If a Check Engine Light was present for an evaporative emission code, clear the code with a scan tool and drive the vehicle through at least one complete drive cycle to verify the light does not return
• Check that no fuel odor is present around the fuel filler area after installation

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