Replacing Fuel Pump In '99 Rav4: Step-By-Step Guide

If your 1999 Toyota RAV4 is experiencing issues such as a whirring noise from the fuel tank, stalling, or failing to start, you may need to replace the fuel pump. The fuel pump is located inside the fuel tank and supplies pressurised gasoline to the engine. While it is possible to replace the fuel pump yourself, it is recommended that you let a repair shop handle this job due to the risk of fire. The cost of replacing a fuel pump can vary depending on your location, but the average cost for a Toyota RAV4 fuel pump replacement is around $540, with parts costing $155 and labour costing $385.

Disconnect the battery

Disconnecting the battery is the first step in replacing the fuel pump of a 1999 Toyota Rav4. This is a crucial safety precaution to reduce the chance of a fire when working on fuel system repairs. Here is a detailed, step-by-step guide on how to do this safely and effectively:

Step 1: Locate the Battery

The battery is typically located in the engine bay, which can be accessed by opening the hood of your Toyota Rav4. It is usually in a rectangular, black plastic case with two terminals protruding from it, marked positive (+) and negative (-).

Step 2: Gather the Necessary Tools

Before you begin, ensure you have the right tools for the job. You will need a basic set of hand tools, including a wrench or socket set to loosen and tighten the battery terminals, as well as a pair of safety gloves and eye protection for your own safety.

Step 3: Prepare the Work Area

Park your car on a level surface and engage the parking brake. Make sure the engine is off, and you are wearing the appropriate safety gear. Place a suitable container or pan underneath the battery to catch any spilled fluids.

Step 4: Disconnect the Negative terminal

Using your wrench or socket, loosen the nut on the negative (-) battery terminal. Carefully remove the cable from the terminal, ensuring that it does not touch any metal parts of the car. You may need to wiggle the cable free gently. Once removed, secure the cable away from the battery, ensuring it cannot accidentally make contact.

Step 5: Disconnect the Positive Terminal

Following the same procedure, loosen and remove the cable from the positive (+) battery terminal. Again, ensure that the cable is secured away from the battery and cannot make contact.

Step 6: Clean the Battery Terminals

With the cables disconnected, take the opportunity to clean the battery terminals. You can use a wire brush or a mixture of baking soda and water to remove any corrosion or buildup on the terminals. This will help ensure a good connection when you reinstall the battery.

Step 7: Store the Battery Safely

If you are not immediately reconnecting the battery, store it in a safe, secure place, out of the reach of children and pets. Keep the battery upright and ensure it does not roll or tip over. Do not place the battery on a concrete floor, as it can drain the charge.

Remember, working on your fuel system can be dangerous, and you should always take the necessary precautions to prevent accidents. When in doubt, consult a qualified mechanic or seek professional assistance.

Remove the access cover

To remove the access cover of your 1999 Toyota RAV4, start by disconnecting the battery to reduce the chance of a fire. This is an important safety precaution when working on any part of a vehicle's fuel system.

Next, locate the access cover. The fuel pump is located inside the fuel tank, so the access cover will be found either above the tank in the passenger compartment or, if no access panel exists, you will need to remove the fuel tank from the vehicle.

If your RAV4 has an access panel, simply remove it by unscrewing or otherwise detaching it. With the cover off, you will be able to access the fuel pump and pre-pump filter screen for replacement.

In some cases, you may need to drain the fuel before removing the access panel. This is to prevent spillage and is a standard safety measure when working with vehicle fuel systems. Ensure you are in a well-ventilated area and refer to your owner's manual for specific instructions on how to safely drain fuel from your vehicle.

If your vehicle does not have an access panel, you will need to lower and remove the fuel tank to access the pump. This process may vary depending on your vehicle's specific configuration, so it is recommended to refer to a repair manual or seek the assistance of a qualified mechanic.

Remember to take all necessary precautions when working with the fuel system to prevent the risk of fire.

Drain the fuel

To drain the fuel from a 1999 Toyota Rav4, you will need to remove the fuel pump through the access panel above the tank in the passenger compartment.

First, disconnect the battery to reduce the chance of a fire. Then, remove the access panel and take out the fuel pump. Place a container underneath the tank to catch the drained fuel. You can then use a fuel pump to drain the tank. Ensure you are wearing protective clothing and that the area is well-ventilated.

Alternatively, you can drain the tank by drilling a hole in it, but this will be more time-consuming and costly.

Once the tank is drained, you can proceed with replacing the fuel pump.

Remove the fuel pump

To remove the fuel pump from a 1999 Toyota Rav4, you will first need to disconnect the battery to reduce the chance of a fire. Next, you will need to access the pump. The pump may be inside or outside the fuel tank.

If the pump is inside the fuel tank, you will need to remove the access cover in the top of the tank, which is located in the passenger compartment. In some cases, you will need to drain the fuel tank before removing the access panel.

If the pump is outside the tank, simply disconnect the fuel lines and remove the pump.

Once you have accessed the pump, you will need to remove the fuel pump supply and return hoses, as well as the EVAP system hoses and electrical connections to the pump.

After the pump is out, you can install the new pump.

Install the new fuel pump

To install the new fuel pump, follow these steps:

First, ensure that the new fuel pump is compatible with your 1999 Toyota RAV4. Check the manufacturer's instructions or consult a mechanic if you are unsure.

Next, carefully lower the new fuel pump into the fuel tank. If your vehicle has an access panel, you may not need to lower the entire tank. Position the pump in the correct location, ensuring any reusable brackets and pick-up screens are attached securely.

Once the new pump is in place, reconnect the fuel pump supply and return hoses, EVAP system hoses, and electrical connections. Refer to your vehicle's repair manual or a trusted mechanic if you are unsure about specific connections.

After everything is connected, refill the fuel tank and start the engine. Check for any fuel leaks and ensure that the problem is resolved. Test-drive the vehicle to confirm that the new fuel pump is functioning correctly.

If you are uncomfortable or unfamiliar with any of these steps, it is recommended to consult a professional mechanic to ensure a safe and proper installation.

Frequently asked questions