This procedure removes and replaces the fuel pump assembly by accessing it through the rear seat access panel, eliminating the need to drop the fuel tank on 2019-2024 RAV4 models.

Warnings

Tools required

Parts

• Fuel pump assembly × 1 — Toyota 77020-0R040 or equivalent
• Fuel pump seal/gasket × 1 — Included with fuel pump assembly

Preparation

1. Ensure fuel level is below 1/4 tank. If above, siphon or drive vehicle to reduce fuel level
2. Park vehicle on level surface, apply parking brake, and chock wheels
3. Have fire extinguisher immediately accessible to work area
4. Ensure adequate ventilation in work area - open garage doors or work outdoors
5. Disconnect negative battery terminal and wait 90 seconds for SRS system to discharge
6. Relieve fuel system pressure by removing fuel pump relay (EFI2 - 15A in engine compartment fuse box) and attempting to start engine until it dies, then crank for 5 additional seconds
7. Reinstall fuel pump relay after pressure relief

Procedure

1. 1

   Remove rear seat cushion bottom
   Pull up firmly on the front edge of the rear seat cushion bottom near the outboard corners to disengage the two retaining clips. Lift the seat cushion up and remove it from the vehicle. This exposes the carpeted floor panel.
2. 2

   Access fuel pump service cover
   Fold back or cut the carpet along the factory perforations to expose the rectangular plastic access cover on the driver's side of the floor panel. The cover is approximately 10 inches by 8 inches and located toward the rear of the cabin.
3. 3

   Remove access cover
   Remove the Phillips head screws securing the fuel pump access cover (typically 4-6 screws). Carefully lift the cover away. You will now see the top of the fuel pump module with fuel lines and electrical connector attached.
   ⚠Fuel vapors will be present. Ensure no ignition sources are nearby.
4. 4

   Disconnect electrical connector
   Press the lock tab on the fuel pump electrical connector and carefully pull the connector straight up off the pump module. Place it aside where it will not contact fuel.
5. 5

   Disconnect fuel supply line
   Using the appropriate fuel line disconnect tool, press the release tabs on the fuel supply quick-connect fitting while pulling the line straight away from the pump module. Have shop towels ready as residual fuel will spill. Plug the line with a clean rag to prevent contamination.
   ⚠Residual fuel under slight pressure may spray. Keep face clear and have towels ready.
6. 6

   Disconnect fuel return/vent line
   Using the fuel line disconnect tool, release the return/vent line quick-connect fitting from the pump module. Again, have shop towels ready for fuel spillage. Plug the line opening.
   ⚠More fuel will spill. Use drain pan and absorbent materials.
7. 7

   Remove fuel pump lock ring
   Install the fuel pump lock ring tool (SST 09808-14020 or equivalent) onto the lock ring tabs. Strike the tool counterclockwise with a plastic mallet or use a breaker bar to loosen the lock ring. Once loose, unthread the lock ring by hand and remove it completely. Note the orientation of any alignment marks.
   ⚠Do not use metal hammer directly on lock ring as sparks can ignite fuel vapors. Use plastic mallet only.
8. 8

   Remove fuel pump assembly
   Carefully lift the fuel pump assembly straight up and out of the tank opening. Tilt it slightly to navigate the fuel level float arm through the opening. Fuel will drain from the assembly - have drain pan positioned to catch it. Remove the old seal/gasket from the tank opening and discard.
   ⚠Do not bend or damage the fuel level sender arm during removal. Significant fuel will drain from assembly into tank and work area.
9. 9

   Inspect fuel tank opening
   Inspect the fuel tank flange and sealing surface for damage, debris, or corrosion. Clean the sealing surface with a lint-free cloth. Check inside the tank opening for any debris that may have fallen in and remove if present.
10. 10

    Install new fuel pump assembly
    Install the new seal/gasket onto the fuel pump assembly (or onto the tank flange per manufacturer instructions). Carefully lower the new fuel pump assembly into the tank opening, guiding the fuel level float arm through the opening. Ensure the assembly is fully seated and any alignment marks or tabs are properly positioned.
    ⚠Verify seal is properly positioned and not pinched. A compromised seal will cause fuel leaks and vapor codes.
11. 11

    Install and torque lock ring
    Thread the fuel pump lock ring onto the tank flange by hand, ensuring it threads smoothly. Install the lock ring tool and torque the lock ring to specification (68 Nm / 50 lb-ft) in a clockwise direction. Verify the lock ring is fully seated against the tank flange.
12. 12

    Reconnect fuel lines
    Remove plugs from fuel lines. Push the fuel supply line quick-connect fitting onto the pump module until you hear and feel a distinct click. Tug gently to verify it is locked. Repeat for the fuel return/vent line. Ensure both connections are secure.
    ⚠Incomplete connection of quick-connect fittings will cause fuel leaks under pressure. Verify positive click and pull-test both lines.
13. 13

    Reconnect electrical connector
    Push the electrical connector onto the fuel pump module until the lock tab clicks into place. Verify the connection is secure by gently pulling on the connector.
14. 14

    Reinstall access cover
    Position the access cover over the opening and install all screws. Torque the screws to specification (4.0 Nm / 3.0 lb-ft) in a cross pattern to ensure even sealing. Reposition the carpet over the access cover.
15. 15

    Reinstall rear seat and reconnect battery
    Reinstall the rear seat cushion by engaging the retaining clips - push down firmly until clips lock. Reconnect the negative battery terminal.

Reassembly

1. Clean up any spilled fuel immediately with absorbent materials and dispose of properly
2. Remove all tools and materials from vehicle
3. Ensure all fuel-soaked materials are stored in approved metal container away from building

Verification

• Turn ignition to ON position (do not start) and listen for fuel pump priming for 2-3 seconds. Repeat key cycle 3-4 times to pressurize system
• Inspect fuel pump access area, all line connections, and lock ring for any fuel leaks
• Start engine and let idle for 2 minutes while monitoring for leaks, unusual noises, or fuel odors
• Check for diagnostic trouble codes using OBD-II scanner - verify no fuel system codes present
• Test drive vehicle and verify normal acceleration and fuel system operation
• After test drive, perform final inspection of all connections and access cover area for leaks
• Monitor fuel gauge operation to verify fuel level sender is functioning correctly

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