Fuel Filler Neck

This procedure covers the removal and replacement of the fuel filler neck on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine, including disconnection of hoses and mounting hardware.

Warnings

Tools required

Parts

• Fuel filler neck assembly × 1 — 77201-42070 or equivalent OEM
• Fuel filler neck gasket × 1 — Use OEM specification
• Hose clamps (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Ensure fuel tank is less than half full to minimize spillage (drain if necessary)
3. Allow exhaust system to cool completely if vehicle was recently driven
4. Disconnect negative battery terminal and wait 90 seconds
5. Raise rear of vehicle and secure on jack stands at manufacturer lift points
6. Remove rear driver side wheel for better access to filler neck area
7. Remove fuel filler door and any interior trim panels that obstruct access to filler neck from inside cargo area

Procedure

1. 1

   Remove fuel cap and access panel
   Remove the fuel cap and set aside. From inside the cargo area, remove the driver side rear interior trim panel to access the upper filler neck mounting area. Remove the plastic access cover by removing the screws securing it.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
2. 2

   Disconnect filler neck hoses from tank side
   Locate the fuel tank vapor hose and breather hose connections at the tank end. Use hose clamp pliers to reposition the spring clamps away from the connections. Carefully twist and pull the hoses off the tank fittings. Have a drain pan ready to catch any residual fuel.
   ⚠Expect fuel spillage when disconnecting hoses. Keep drain pan positioned under connections.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
3. 3

   Disconnect electrical connector
   Locate the fuel tank pressure sensor electrical connector near the filler neck assembly. Press the locking tab and disconnect the connector. Secure the connector out of the way to prevent damage.
4. 4

   Remove filler neck upper mounting hardware
   From inside the cargo area, remove the bolts securing the upper portion of the filler neck to the body. There are typically two bolts accessible from this location. Support the filler neck as you remove the final bolt.
   Torque spec

   Filler Neck Bolts10 Nm (7 lb-ft)
5. 5

   Remove filler neck lower mounting bracket
   Working from underneath the vehicle, locate the filler neck mounting bracket attached to the chassis. Remove the bracket bolts securing the filler neck assembly to the frame rail. Keep track of any spacers or washers.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
6. 6

   Disconnect filler neck from fuel tank
   Locate where the filler neck enters the fuel tank. Remove the bolts or clamp securing the filler neck to the tank inlet. Carefully wiggle and pull the filler neck rubber grommet from the tank opening. Allow any remaining fuel to drain into your catch pan.
   ⚠The filler neck may contain residual fuel. Drain completely before removing from vehicle.
   Torque spec

   Filler Neck Bolts10 Nm (7 lb-ft)
7. 7

   Remove filler neck assembly
   Carefully maneuver the filler neck assembly out through the wheel well area, feeding it down and out from the body. You may need to rotate and angle the assembly to clear body panels and suspension components. Inspect the removed assembly for cracks, corrosion, or damage.
8. 8

   Prepare new filler neck for installation
   Compare the new filler neck to the old unit to verify correct part. Install a new gasket or grommet onto the tank inlet end of the new filler neck. Lubricate the grommet lightly with soapy water to ease installation (never use petroleum-based lubricants near fuel systems).
9. 9

   Install new filler neck assembly
   Maneuver the new filler neck into position through the wheel well, routing it along the same path as the original. Insert the tank end into the fuel tank opening, ensuring the gasket seats properly. Align all mounting points before tightening any fasteners.
10. 10

    Secure filler neck to fuel tank
    Install and hand-tighten the bolts or clamp securing the filler neck to the fuel tank inlet. Ensure the gasket is properly seated and the neck is fully inserted. Torque the filler neck bolts to specification in a cross pattern.
    Torque spec

    Filler Neck Bolts10 Nm (7 lb-ft)
11. 11

    Install lower mounting bracket
    Position the filler neck mounting bracket to the chassis and install the bracket bolts. Ensure any spacers or washers are in their correct positions. Torque the bracket bolts to specification.
    Torque spec

    Bracket Bolts20 Nm (15 lb-ft)
12. 12

    Install upper mounting hardware
    From inside the cargo area, install the upper filler neck mounting bolts. Ensure the filler neck is properly aligned with the filler door opening before final tightening. Torque the filler neck bolts to specification.
    Torque spec

    Filler Neck Bolts10 Nm (7 lb-ft)
13. 13

    Reconnect hoses and electrical connector
    Reconnect the vapor hose and breather hose to the filler neck, ensuring they are fully seated onto the fittings. Position the hose clamps over the connection points and secure them. Reconnect the fuel tank pressure sensor electrical connector until it clicks.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
14. 14

    Reinstall access panels and wheel
    Install the plastic access cover inside the cargo area and secure with screws to specification. Reinstall the interior trim panel. Reinstall the rear driver side wheel and torque lug nuts to specification. Lower the vehicle.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Reconnect the negative battery terminal
2. Install the fuel filler cap
3. Verify all tools and parts have been removed from the work area
4. Check that all mounting hardware is tight and properly torqued

Verification

• Add 2-3 gallons of fuel to the tank and check all connections for leaks
• With the fuel cap removed, have an assistant turn the ignition to ON (engine off) and listen for the fuel pump to prime while observing for leaks at all filler neck connections
• Start the engine and verify no fuel odor or visible leaks
• Check that the fuel cap seals properly and the fuel door closes correctly
• Clear any DTCs related to fuel tank pressure if necessary using a scan tool
• Test drive the vehicle and verify no fuel smell in the cabin or check engine light illumination

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