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Removal & Installation and Disassembly & Reassembly

WARNING: This page is about a different car, the 2004 Toyota Corolla. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE BENCH TYPE REAR SEAT CUSHION ASSY (See  OVERHAUL (W/SEPARATE TYPE)  or  OVERHAUL (W/BENCH TYPE)  ) 
  2. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the rear service hole cover.
      Fig 1: Identifying Bugle Tape
      G02898706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel pump and vapor pressure sensor connector.
    Fig 2: Disconnecting Fuel Pump And Vapor Pressure Sensor Connector
    G02898707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT 
    1. Start the engine.
    2. After the engine has stopped on the its own, turn the ignition switch to lock.
  4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY 
    1. Remove the tube joint clip, and pull out the fuel tank main tube.
    NOTE:
    • Check if there is any dirt like mud around the fuel tube joint before this work and clean dirt away.
    • Be careful of dirt like mud because the fuel tube joint has an O-ring to seal the fuel tube joint and fuel suction plate.
    • Do not use any tool in this work.
    • Do not bend or twist the nylon tube by force.
    • After disconnecting, cover the fuel tube joint with a vinyl bag.
    • When the fuel tube joint and fuel suction plate are stuck, pinch the fuel tank main tube between fingers, and turn it carefully to free and then disconnect the fuel tank main tube.
    Fig 3: Pulling Out Fuel Tank Main Tube
    G02898708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 4: Identifying Fuel Tube Joint And Nylon Tube
    G02898709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. DISCONNECT FUEL EMISSION TUBE SUB-ASSY NO.1 
    1. Pinch the fuel tube connector clip and then pull out the fuel emission tube.
    NOTE:
    • Check if there is any dirt like mud around the fuel tube connector before this work and clean dirt away.
    • Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.
    • Do not use any tool in this work.
    • Do not bend or twist the nylon tube by force.
    • After disconnecting, cover the fuel tube connector with a vinyl bag.
    • When the fuel tube connector and pipe are stuck, pinch the fuel emission tube between fingers, and turn it carefully to free and then disconnect the fuel emission tube.
    Fig 5: Disconnecting Fuel Emission Tube Sub-Assy
    G02898710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 6: Identifying Fuel Tube Connector And Nylon Tube
    G02898711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL TANK VENT TUBE SET PLATE 
    1. Remove the 8 bolts and fuel tank vent tube set plate.
    Fig 7: Removing Bolts And Fuel Tank Vent Tube Set Plate
    G02898712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FUEL PUMP ASSEMBLY 
    1. Pull out the fuel pump assembly.
    NOTE:
    • Do not damage the fuel pump filter.
    • Be careful that the arm of the fuel sender gauge should not bent.
    Fig 8: Pulling Out Fuel Pump Assembly
    G02898713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL SUCTION TUBE SET GASKET 
    1. Remove the gasket from the fuel pump assembly.
    Fig 9: Identifying Fuel Pump Assembly
    G02898714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL SUCTION SUPPORT NO. 2 
    1. Using a screwdriver, disconnect the 5 snap claws from the claw holes, and remove the fuel suction support.
    NOTE: Do not damage the fuel suction support.
    Fig 10: Removing Fuel Suction Support
    G02898715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FUEL PUMP CUSHION RUBBER 
    1. Remove the fuel pump cushion rubber.
    Fig 11: Removing Fuel Pump Cushion Rubber
    G02898716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL SENDER GAGE ASSY 
    1. Disconnect the fuel sender gage connector.
    2. Using a screwdriver, unlock the fuel sender gage, and slide it remove.
    Fig 12: Disconnecting Fuel Sender Gage Connector
    G02898717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL SUCTION PLATE SUB-ASSY 
    1. Disconnect the fuel pump connector.
    2. Using a screwdriver, disconnect the 4 snap claws from the claw holes, and remove the fuel suction plate.
    NOTE: Do not damage the fuel suction plate.
    Fig 13: Removing Fuel Suction Plate Sub-Assy
    G02898718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE VAPOR PRESSURE SENSOR ASSY 
    1. Remove the tube joint clip, and pull out the vapor pressure sensor.
    Fig 14: Pulling Out Vapor Pressure Sensor
    G02898719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FUEL PUMP HARNESS 
    1. Remove the fuel pump harness from the fuel suction plate.
    Fig 15: Removing Fuel Pump Harness From Fuel Suction Plate
    G02898720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL PUMP 
    1. Pull out the fuel pump from the fuel filter.
    Fig 16: Pulling Out Fuel Pump From Fuel Filter
    G02898721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FUEL PUMP FILTER 
    1. Using a small screwdriver, pry out the clip.
    2. Pull out the fuel pump filter from the fuel pump.
    Fig 17: Pulling Out Fuel Pump Filter From Fuel Pump
    G02898722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FUEL PRESSURE REGULATOR ASSY 
    1. Pull out the fuel pressure regulator from the fuel filter.
    Fig 18: Pulling Out Fuel Pressure Regulator From Fuel Filter
    G02898723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FUEL PRESSURE REGULATOR O-RING 
    1. Remove an O-ring from the fuel pressure regulator.
    Fig 19: Identifying Fuel Pressure Regulator
    G02898724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FUEL PRESSURE REGULATOR O-RING 
    1. Apply a light coat of gasoline to a new O-ring, and install it to the fuel pressure regulator.
    Fig 20: Applying Light Coat Of Gasoline To New O-Ring
    G02898725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL FUEL PUMP FILTER 
    1. Install the fuel pump filter with a new clip.
  21. INSTALL FUEL PUMP 
    1. Apply a light coat of gasoline to an O-ring, and install the fuel pump to the fuel filter.
    Fig 21: Identifying Light Coat Of Gasoline On O-Ring
    G02898726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL VAPOR PRESSURE SENSOR ASSY 
    1. Install the vapor pressure sensor with the tube joint clip.
    NOTE:
    • Check that there is no scratch or foreign objects on the connecting parts.
    • Check that the fuel tube joint is inserted fully and securely.
    • Check that the tube joint clip is on the collar of the fuel tube joint.
    • After installing the tube joint clip, check that the fuel tube joint is not pulled off.
  23. INSTALL FUEL SUCTION TUBE SET GASKET 
    1. Install a new gasket to the fuel pump assembly.
  24. INSTALL FUEL PUMP ASSEMBLY 
    1. Install the fuel pump assembly to the fuel tank.
    NOTE:
    • Do not damage the fuel pump filter.
    • Be careful that the arm of the fuel sender gauge should not bent.
  25. INSTALL FUEL TANK VENT TUBE SET PLATE 
    1. Install the fuel tank vent tube set plate with the 8 bolts.

      Torque: 6.0 N.m (61 kgf.cm, 53 in..lbf) 

  26. CONNECT FUEL EMISSION TUBE SUB-ASSY NO.1 
    1. Push in the fuel emission tube to the pipe until fuel tube connector makes "click" sound.
    NOTE:
    • Check if there is any damage or foreign objects on the connected part.
    • After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
  27. CONNECT FUEL TANK MAIN TUBE SUB-ASSY 
    1. Connect the fuel tank main tube with the tube joint clip.
    NOTE:
    • Check that there is no scratch or foreign objects on the connecting parts.
    • Check that the fuel tube joint is inserted fully and securely.
    • Check that the tube joint clip is on the collar of the fuel tube joint.
    • After installing the tube joint clip, check that the fuel tube joint is not pulled off.
  28. CHECK FUEL LEAK (See  FUEL SYSTEM  ) 
  29. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Using the butyl tape, install the rear floor service hole cover.
    Fig 22: Installing Rear Floor Service Hole Cover
    G02898727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL BENCH TYPE REAR SEAT CUSHION ASSY (See  OVERHAUL (W/SEPARATE TYPE)  or  OVERHAUL (W/BENCH TYPE)  ) 
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