This procedure covers removal and replacement of the fuel tank mounting straps on a 2019-2024 Toyota RAV4 with 2.5L I4 engine, requiring fuel tank lowering and proper support.

Warnings

Tools required

Parts

• Fuel tank strap (left) × 1 — Toyota 77251-42030 or equivalent
• Fuel tank strap (right) × 1 — Toyota 77252-42030 or equivalent
• Fuel line O-rings × 2 — Use OEM specification
• Fuel filler neck O-ring × 1 — Use OEM specification

Preparation

1. Ensure fuel tank is at 1/4 tank or less. If tank is fuller, safely siphon or drain fuel into approved containers before beginning work
2. Park vehicle on level, solid surface and engage parking brake
3. Disconnect negative battery terminal and wait 90 seconds for system depressurization
4. Remove fuel pump relay (EFI No.2 relay, 15A in engine compartment fuse box) and start engine to run until it stalls, relieving fuel system pressure. Crank engine 2-3 more times to ensure complete depressurization
5. Raise vehicle and support securely on jack stands at manufacturer-recommended lift points. Ensure minimum 24 inches of clearance under vehicle
6. Remove rear wheels for better access to tank mounting area
7. Position transmission jack or fuel tank support jack under center of fuel tank but do not raise yet
8. Place drain pan under fuel line connections in case of residual fuel spillage
9. Inspect fuel tank straps and mounting points for severe corrosion. If excessive rust is present, this repair may require additional welding or structural work

Procedure

1. 1

   Disconnect fuel filler neck and vent lines
   Locate the fuel filler neck connection at the rear driver side of the tank. Loosen the hose clamp securing the filler neck to the tank using a flathead screwdriver or 7mm socket. Carefully twist and pull the filler neck away from the tank grommet. Disconnect the vent line from the tank by pressing the release tab and pulling away. Inspect the filler neck O-ring and replace if damaged.
   Torque spec

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

   Disconnect fuel supply and return lines
   Locate the fuel line connections on top of the fuel tank near the fuel pump assembly. Using the appropriate fuel line disconnect tool, press the release tabs and carefully pull each quick-disconnect fitting straight off. Be prepared for residual fuel spillage. Wipe connections clean and inspect for damage. Mark or photograph connections to ensure correct reassembly orientation.
   ⚠Even after pressure relief, residual fuel will spill from lines. Have shop rags ready and avoid getting fuel on skin or clothing.
3. 3

   Disconnect fuel pump electrical connector
   Locate the fuel pump electrical connector on top of the fuel tank. Press the locking tab and disconnect the connector. If connector is difficult to access, you may need to remove the access panel from inside the vehicle by lifting the rear seat cushion and removing the cover screws. Move the wiring harness safely out of the way.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
4. 4

   Disconnect EVAP canister lines
   Locate the EVAP vapor lines connected to the front of the fuel tank. These are typically quick-disconnect fittings. Press the release tabs and disconnect each line. There are typically 2-3 EVAP lines depending on emissions equipment. Label each connection to ensure correct reinstallation.
   ℹ️EVAP lines are fragile plastic. Do not use excessive force or they may crack.
5. 5

   Support fuel tank with jack
   Position the transmission jack or fuel tank support jack to cradle the center of the fuel tank. Raise the jack until it just contacts the tank bottom with light pressure, but is not supporting the full weight yet. Ensure the tank is balanced and stable on the jack. Use a wide wooden board on the jack saddle if necessary to distribute load evenly.
   ⚠️The tank must be properly balanced on the jack. An unbalanced tank can shift suddenly when straps are loosened, causing injury.
6. 6

   Remove fuel tank heat shield
   If equipped, remove the heat shield mounted to the bottom of the fuel tank. Remove the mounting bolts (typically 10mm) securing the shield. Lower the heat shield and set aside. Inspect shield for damage and clean mounting surfaces.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
7. 7

   Remove fuel tank strap bolts
   Locate the fuel tank strap mounting bolts at each end of both straps. These are typically 14mm bolts threaded into captive nuts in the body. There are two straps running front-to-back under the tank. Apply penetrating oil if bolts show corrosion. Remove the rear bolt from each strap first, then the front bolts. Support the strap ends as you remove the final bolts to prevent them from falling.
   ⚠Strap bolts may be severely corroded. If a bolt breaks or strips, extraction may be required before proceeding.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
8. 8

   Remove old fuel tank straps
   With all mounting bolts removed and the tank supported on the jack, carefully lower the jack approximately 4-6 inches to create clearance. The tank will pivot slightly forward. Remove both straps from around the tank by sliding them toward the rear and out. Inspect the strap mounting points on the vehicle body for damage or severe rust. Clean mounting surfaces with a wire brush.
   ⚠️Maintain control of the jack at all times. Lower slowly and ensure tank remains stable and balanced.
9. 9

   Inspect tank and mounting surfaces
   With straps removed and tank lowered, thoroughly inspect the fuel tank body for damage, dents, or rust perforation. Check the tank mounting brackets welded to the body for cracks or excessive corrosion. Clean all mounting surfaces with a wire brush. If any structural damage is found, consult a professional before proceeding. This is the opportunity to replace other tank components if needed.
10. 10

    Install new fuel tank straps
    Position the new fuel tank straps around the tank while it is lowered on the jack. Route the straps so they will align with the mounting brackets when the tank is raised. Compare new straps to old ones to confirm correct positioning. The straps should have rubber insulators or protective coating where they contact the tank.
    ℹ️Ensure strap orientation is correct. The curved profile must match the tank contour and bolt holes must align with body brackets.
11. 11

    Raise tank and start strap bolts
    Carefully raise the fuel tank using the jack, ensuring all previous connections (filler neck, EVAP lines, fuel lines, electrical) have clearance and are not pinched. Align the tank to its mounting position. Thread the strap mounting bolts by hand into the body brackets. Start all four bolts (two per strap) before tightening any. Ensure straps are positioned correctly and not twisted.
    ⚠Do not fully tighten bolts yet. Tank must be properly positioned and all connections verified before final torque.
12. 12

    Torque fuel tank strap bolts
    Using a torque wrench, tighten all four fuel tank strap mounting bolts to specification in a cross pattern (front-left, rear-right, front-right, rear-left). This ensures even loading of the tank. Verify straps are seated properly against the tank and body brackets. The tank should be secure with no movement when pulled gently.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
13. 13

    Reinstall heat shield
    If equipped, position the fuel tank heat shield back onto the bottom of the tank. Install and torque the mounting bolts to specification. Ensure the heat shield does not contact the exhaust system and has proper clearance.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
14. 14

    Reconnect all fuel lines and hoses
    Install new O-rings on all fuel line connections (supply and return lines). Lubricate O-rings lightly with clean fuel or approved lubricant. Reconnect fuel supply and return lines by pushing quick-disconnect fittings straight onto the tank ports until an audible click is heard. Tug on each line to verify secure connection. Reconnect all EVAP canister vapor lines using the same method. Reconnect the fuel filler neck to the tank with new O-ring if needed, and secure with hose clamp.
    ⚠Always use new O-rings on fuel connections. Reusing old O-rings can cause leaks and fire hazard.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)

    Hose Clamps3 Nm (2 lb-ft)
15. 15

    Reconnect electrical connector
    Reconnect the fuel pump electrical connector on top of the fuel tank. Ensure the connector locks securely with an audible click. If an access panel was removed from inside the vehicle, reinstall it with cover screws torqued to specification. Verify the wiring harness has proper routing and is not pinched or stretched.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Carefully remove the fuel tank support jack from under the vehicle
2. Reinstall rear wheels and torque lug nuts to 103 Nm (76 lb-ft) in a star pattern
3. Lower vehicle from jack stands to ground
4. Reinstall fuel pump relay (EFI No.2 relay) in engine compartment fuse box
5. Reconnect negative battery terminal
6. Double-check that all tools and equipment have been removed from under vehicle

Verification

• With vehicle still outdoors or in well-ventilated area, turn ignition to ON position (do not start) for 5 seconds to prime fuel system. Repeat 3-4 times. Listen for fuel pump operation
• Using a flashlight and inspection mirror, carefully check all fuel line connections, filler neck, and EVAP connections for any signs of fuel leakage. Look for wet spots or fuel odor
• Start the engine and let it idle for 2-3 minutes while continuing to monitor all connections for leaks
• Perform a visual inspection under the vehicle while engine is running. Check that fuel tank is properly secured and straps are not contacting exhaust components
• Turn off engine and perform final leak check of all connections. Any fuel odor or visible leak requires immediate attention before driving
• Test drive the vehicle for 5-10 minutes, listening for any unusual noises from the fuel tank area (rattles, scraping). Tank should be completely secure with no movement
• After test drive, perform final inspection of all connections and verify no fuel leaks have developed
• Monitor fuel level gauge to ensure fuel pump is functioning correctly and no electrical issues are present

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