This procedure removes and replaces the fuel pump module assembly on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine, accessed through a service panel under the rear seat.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Toyota 77020-0R090 or equivalent
• Fuel pump module gasket/O-ring × 1 — Use OEM specification
• Fuel line O-rings (quick connect type) × 2 — Use OEM specification

Preparation

1. Verify fuel tank is less than 1/4 full. If needed, siphon or drain excess fuel using approved equipment into approved containers
2. Park vehicle on level ground in a well-ventilated area away from ignition sources
3. Position Class B fire extinguisher within immediate reach
4. Disconnect negative battery terminal and wait 90 seconds for airbag system capacitors to discharge
5. Remove rear seat cushion by pulling up firmly on front edge to release retaining clips
6. Place absorbent pads or shop towels under the work area to catch fuel spillage

Procedure

1. 1

   Relieve fuel system pressure
   With the battery disconnected, remove the fuel pump relay from the engine bay fuse box (relay location varies by model year - consult owner's manual). Reconnect battery temporarily, start the engine and let it run until it stalls from fuel starvation. Attempt to restart 2-3 times to ensure pressure is fully relieved. Turn ignition off and disconnect the negative battery terminal again.
   ⚠️Engine must stall on its own. Do not simply turn off ignition or pressure will remain in the system.
2. 2

   Remove access cover
   Locate the rectangular access cover in the floor under the rear seat. Remove the Phillips head screws securing the access cover (typically 4-6 screws). Carefully peel back any sound deadening material if present. Lift the access cover to expose the fuel pump module.
   ℹ️Sound deadening material can be reused if removed carefully. Clean any debris from the exposed area before proceeding.
   Torque spec

   Access Cover Screws4 Nm (3 lb-ft)
3. 3

   Disconnect electrical connector
   Press the locking tab on the fuel pump module electrical connector and disconnect it from the pump assembly. Move the connector aside to prevent fuel contamination. Inspect the connector for corrosion or damage.
4. 4

   Disconnect fuel supply line
   Using the appropriate fuel line disconnect tool, release the quick-connect fitting on the fuel supply line. Press the tool into the fitting while pulling the line away from the pump module. Have shop towels ready to catch residual fuel (approximately 50-100ml may spill). Cap or plug the line to prevent contamination.
   ⚠Residual fuel under pressure may spray out. Wear safety glasses and keep face away from the connection point.
5. 5

   Disconnect fuel return/vent line
   Using the fuel line disconnect tool, release the quick-connect fitting on the return/vent line (smaller diameter line). Remove the line from the pump module using the same technique as the supply line. Cap or plug the line opening.
6. 6

   Remove fuel pump lock ring
   Install the fuel pump lock ring tool onto the lock ring tabs. Turn the lock ring counterclockwise to loosen. The lock ring may be tight due to corrosion or fuel residue. Once loosened by hand, remove the tool and unthread the lock ring completely by hand. Lift the lock ring out of the tank opening.
   ⚠Do not use impact tools or strike the lock ring tool as this can generate sparks. Use steady manual pressure only.
   Torque spec

   Fuel Pump Lock Ring68 Nm (50 lb-ft)
7. 7

   Remove fuel pump module assembly
   Carefully lift the fuel pump module straight up and out of the tank opening. The module is approximately 10-12 inches long. Tilt it slightly as needed to clear the tank opening, but avoid bending the fuel level sender arm. Allow fuel to drain back into the tank. Place the old module in a container to catch residual fuel drips.
   ⚠The fuel level sender float arm extends from the module and can be easily bent. Handle with care to avoid damage.
8. 8

   Remove and inspect old gasket
   Remove the old rubber gasket/O-ring from the top of the fuel tank opening. Clean the sealing surface on the tank thoroughly using a clean shop towel. Inspect the tank opening for debris, corrosion, or damage. The sealing surface must be completely clean and smooth for proper seal.
9. 9

   Install new gasket and prepare new module
   Place the new gasket/O-ring onto the fuel tank opening, ensuring it seats properly in the groove. Inspect the new fuel pump module for any shipping damage. Verify the fuel level sender arm moves freely and the float is intact. Install new O-rings onto both fuel line ports on the pump module if they were provided separately.
10. 10

    Install new fuel pump module
    Carefully lower the new fuel pump module into the tank opening at a slight angle to clear the opening. Guide the fuel level sender arm to prevent bending. Align the alignment marks or tabs on the module with the tank opening. Press the module down firmly to seat it against the new gasket. Verify the module is fully seated before proceeding.
    ℹ️The module has specific orientation. Match the alignment arrow on the module with the mark on the tank or ensure the electrical connector faces the correct direction for routing.
11. 11

    Install and torque lock ring
    Place the lock ring over the fuel pump module and thread it clockwise by hand until it contacts the tank flange. Install the fuel pump lock ring tool and tighten to the specified torque of 68.0 Nm (50.0 lb-ft). Ensure the lock ring is fully seated and the module cannot rotate.
    ℹ️Use a smooth, steady pull on the torque wrench. The lock ring should seat evenly around the entire circumference.
    Torque spec

    Fuel Pump Lock Ring68 Nm (50 lb-ft)
12. 12

    Reconnect fuel lines
    Connect the fuel supply line (larger diameter) to the pump module. Push the quick-connect fitting straight onto the port until you hear and feel a distinct click. Tug gently to verify it is locked. Connect the return/vent line (smaller diameter) using the same technique. Ensure both connections are secure and properly seated.
    ℹ️If new O-rings were installed on the line fittings rather than the module, ensure they are properly lubricated with clean gasoline before connection.
13. 13

    Reconnect electrical connector
    Connect the electrical connector to the fuel pump module by pushing it firmly onto the module connector until the locking tab clicks into place. Verify the connection is secure by gently pulling on the connector.
14. 14

    Reinstall access cover
    Reposition any sound deadening material that was moved during disassembly. Place the access cover back over the opening and install all Phillips head screws. Torque the screws to 4.0 Nm (3.0 lb-ft) in a cross pattern to ensure even clamping.
    Torque spec

    Access Cover Screws4 Nm (3 lb-ft)

Reassembly

1. Reinstall the rear seat cushion by aligning the retaining clips and pressing down firmly until all clips engage
2. Reinstall the fuel pump relay in the engine bay fuse box
3. Reconnect the negative battery terminal
4. Add fuel if tank was drained below minimum operating level (at least 2 gallons recommended for initial testing)

Verification

• Turn the ignition to ON position (do not start) for 5 seconds, then OFF. Repeat this cycle 3-4 times to prime the fuel system and build pressure. Listen for the fuel pump running during each cycle
• Inspect under the rear seat access area with a flashlight for any fuel leaks around the pump module, lock ring, and fuel line connections
• Start the engine and let it idle. Check again for leaks while engine is running
• Monitor the fuel gauge to verify the fuel level sender is reading correctly
• Take a short test drive and verify normal engine performance with no fuel delivery issues, rough running, or check engine light
• After test drive, perform a final inspection for fuel leaks around all connections. Any fuel smell or visible leaks requires immediate shutdown and repair
• Clear any diagnostic trouble codes that may have been set during the fuel pressure relief process using an OBD-II scanner

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