1996 TOYOTA RAV4 fuel pump

S01834
Gasket
SST (Union)
SST
Fuel Inlet Hose Gasket
SST (Union)
S01835
301 − 347 kPa
S01836
For 5 Minutes After Engine has Stopped
147 kPa
or More SF−6
− SFIFUEL PUMP
1996 RAV4 (RM447U)
(f) Install the fuel inlet hose and SST (pressure gauge) to the
fuel filter outlet with the 3 gaskets and SST (union bolt).
SST 09268−45012
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(g) Wipe off any splattered gasoline.
(h) Connect the TOYOTA hand−held tester to the DLC3.
(i) Reconnect the negative (−) terminal cable to the battery.
(j) Turn the ignition switch ON.
(k) Measure the fuel pressure.
Fuel pressure:
301 − 347 kPa (3.1 − 3.5 kgf/cm
2, 44 − 50 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check these parts:
Fuel hoses and connections
Fuel pump
Fuel filter
Fuel pressure regulator
(l) Remove the TOYOTA hand−held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle.
Fuel pressure:
301 − 347 kPa (3.1 − 3.5 kgf/cm
2, 44 − 50 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.
Fuel pressure:
147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure
regulator and/or injectors.
(q) After checking fuel pressure, disconnect the negative (−)
terminal cable from the battery and carefully remove the
SST to prevent gasoline from splashing.
SST 09268−45012
(r) Reconnect the fuel inlet hose with 2 new gaskets and the
union bolt.
Torque: 29 N·m (300 kgf·cm, 21 ft·lbf)
(s) Reconnect the negative (−) terminal cable to the battery.
(t) Check for fuel leakage (See page SF−1).
(u) Reinstall the engine comportment R/B No.2 and air clean-
er assembly.
3. CHECK FUEL PUMP
(a) Remove the LH rear seat assembly.
(b) Remove the floor service hole cover.

S01908
Ohmmeter
45
S01914
45
Battery
− SFIFUEL PUMP
SF−7
1996 RAV4 (RM447U)
(c) Disconnect the fuel pump and sender gauge connector.
(d) Inspect the fuel pump resistance.
Using an ohmmeter, measure the resistance between ter-
minals 4 and 5.
Resistance: At 20°C (68°F): 0.2 − 3.0 Ω
If the resistance is not as specified, replace the fuel pump.
(e) Inspect the fuel pump operation.
Connect the positive (+) lead from the battery to terminal
4 of the connector, and the negative (−) lead to terminal
5. Check that the fuel pump operates.
NOTICE:
These tests must be done quickly (within 10 seconds) to
prevent the coil burning out. Keep the fuel pump as far
away from the battery as possible. Always do the switching
at the battery side.
If operation is not as specified, replace the fuel pump or lead
wire.
(f) Reconnect the fuel pump and sender gauge connector.
(g) Reinstall the floor service hole cover.
(h) Reinstall the LH rear seat assembly.

SF0Q6−01
S01937
3 Door Vehicles
LH Rear Seat Assembly5 Door Vehicles
LH Rear Seat Assembly
37 (375, 27)
37 (375, 27)
Rear Seat Hinge Cover
Floor Service Hole Cover
29 (300, 22)
Fuel Pump & Sender
Gauge Connector
 Gasket
Fuel Suction w/ Pump &
Gauge AssemblyFuel Return
Vent Hose Gasket
Fuel Outlet Pipe
x 8
 GasketFuel Hose
Fuel Pump Connector
Ground Strap
Fuel Pump
Fuel Pump Filter
Rubber Cushion  Clip Fuel Pump Clamp
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable part SF−8
− SFIFUEL PUMP
1996 RAV4 (RM447U)
COMPONENTS

SF0Q7−02
S01828(a)
(b)
S01829
− SFIFUEL PUMP
SF−9
1996 RAV4 (RM447U)
REMOVAL
CAUTION:
Do not smoke or work near an open flame when working on
the fuel pump.
1. REMOVE LH REAR SEAT ASSEMBLY
2. REMOVE FLOOR SERVICE HOLE COVER
(a) Take out the floor carpet.
(b) Remove the 4 screws and service hole cover.
HINT:
At the time of installation, plaese refer to the following items.
Check for fuel leakage (See page SF−1).
3. DISCONNECT FUEL PUMP & SENDER GAUGE CON-
NECTOR
4. DISCONNECT FUEL PIPE AND HOSE FROM FUEL
SUCTION TUBE
CAUTION:
Remove the fuel filler cap to prevent the fuel from flowing
out.
(a) Remove the union bolt and 2 gaskets, and disconnect the
outlet pipe from the suction tube.
HINT:
At the time of installation, plaese refer to the following items.
Install the outlet pipe with 2 new gaskets and bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(b) Disconnect the return vent hose from the suction tube.
5. REMOVE FUEL SUCTION w/ PUMP & GAUGE TUBE
ASSEMBLY
(a) Remove the 8 bolts.
Torque: 3.5 N·m (35 kgf·cm, 31 in.·lbf)
(b) Pull out the suction w/ pump & gauge tube assembly.
NOTICE:
Do not damage the fuel pump filter. Be careful that the arm
of the sender gauge should not bent.
(c) Remove the gasket from the set plate.
HINT:
At the time of installation, plaese refer to the following items.
Install a new gasket to the set plate.

SF0Q8−02
S01896
Pull
FI6376
SF−10
− SFIFUEL PUMP
1996 RAV4 (RM447U)
DISASSEMBLY
1. DISCONNECT FUEL PUMP CONNECTOR
2. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET
(a) Disconnect the ground strap from the fuel pump clamp.
(b) Pull off the lower side of the fuel pump from the pump
bracket.
(c) Disconnect the fuel hose from the fuel pump, and remove
the fuel pump.
(d) Remove the rubber cushion from the fuel pump.
3. REMOVE FUEL PUMP CLAMP
4. REMOVE FUEL PUMP FILTER FROM FUEL PUMP
(a) Using a small screwdriver, remove the clip.
(b) Pull out the pump filter.
HINT:
At the time of installation, plaese refer to the following items.
Install the pump filter with a new clip.

SF1QF−01
− SFIFUEL PUMP
SF−11
1996 RAV4 (RM447U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page SF−10 ).

SF1QG−01
SF−12
− SFIFUEL PUMP
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page SF−9).

SF0QB−01
S01959
3 Door Vehicles
LH Rear Seat Assembly5 Door Vehicles
LH Rear Seat Assembly
37 (375, 27)
37 (375, 27)
Rear Seat Hinge Cover
Floor Service Hole Cover
29 (300, 22)
Fuel Pump & Sender
Gauge Connector
 Gasket
Fuel Suction w/ Pump &
Gauge Tube AssemblyFuel Return
Vent Hose Gasket
Fuel Outlet Pipe
x 8
 GasketFuel Hose
Fuel Pressure Regulator  O−Ring Fuel Filter
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable partClip
− SFIFUEL PRESSURE REGULATOR
SF−13
1996 RAV4 (RM447U)
FUEL PRESSURE REGULATOR
COMPONENTS