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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 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  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 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  5. DISCONNECT FUEL EMISSION TUBE SUB-ASSY NO.1 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  6. REMOVE FUEL TANK VENT TUBE SET PLATE (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  7. REMOVE FUEL PUMP ASSEMBLY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  8. REMOVE FUEL SUCTION TUBE SET GASKET 
  9. DRAIN FUEL 
  10. REMOVE FLOOR PANEL BRACE FRONT 
    1. Remove the 2 nuts and floor panel brace front.
    Fig 1: Removing Floor Panel Brace Front
    G02898731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE EXHAUST PIPE ASSY FRONT 
    1. Using a clip remover, remove the clip.
    2. Tear off the front floor carpet.
      Fig 2: Identifying Clip And Floor Carpet
      G02898732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the oxygen sensor connector.
    4. Remove the 2 exhaust pipe supports.
    5. Remove the 4 bolts, 4 compression springs and exhaust pipe.
    Fig 3: Removing Exhaust Pipe Assy Front
    G02898733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL TANK PROTECTOR NO. 1 
    1. Remove the 5 bolts and fuel tank protector.
    Fig 4: Removing Fuel Tank Protector
    G02898734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. SEPARATE PARKING BRAKE CABLE ASSY NO. 2 
    1. Remove the 2 installing bolts of the parking brake cable.
    Fig 5: Removing Parking Brake Cable No. 2
    G02898735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. SEPARATE PARKING BRAKE CABLE ASSY NO. 3 
    1. Remove the 2 installing bolts of the parking brake cable.
    Fig 6: Removing Parking Brake Cable No. 3
    G02898736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY 
    1. Pinch the fuel tube connector clip, and remove the fuel tube connector clip.
    2. Pull out the fuel tank main tube.
    NOTE:
    • Check if there is any dirt like mud around the fuel tube connector before this work and clean the 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 tank main tube between fingers, and turn it carefully to free and then disconnect the fuel tank main tube.
    Fig 7: Identifying Fuel Tube Connector Tube Clip
    G02898737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 8: Identifying Fuel Tube Connector And Tube Clip
    G02898738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT FUEL TANK INLET PIPE FUEL HOSE 
    1. Disconnect the fuel tank inlet filler pipe hose from the fuel tank.
    Fig 9: Disconnecting Fuel Tank Inlet Filler Pipe Hose From Fuel Tank
    G02898739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT FUEL TANK BREATHER HOSE 
    1. Disconnect the fuel tank breather hose from the fuel tank.
    Fig 10: Disconnecting Fuel Tank Breather Hose From Fuel Tank
    G02898740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT FUEL TANK VENT HOSE 
    1. Disconnect the fuel tank bent hose from the charcoal canister.
      1. Push the connector deep inside.
      2. Pinch portion A.
      3. Pull out the connector.
    Fig 11: Disconnecting Fuel Tank Bent Hose From Charcoal Canister
    G02898741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. DISCONNECT VALVE TO FUEL FILLER PIPE HOSE 
    1. Disconnect the valve to fuel filler pipe hose from the fuel tank inlet pipe.
    Fig 12: Disconnecting Valve To Fuel Filler Pipe Hose
    G02898742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. 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 the 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 13: Identifying Connector Clip And Fuel Emission Tube
    G02898743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 14: Identifying Fuel Tube Connector, Clip And Nylon Tube
    G02898744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FUEL TANK ASSY 
    1. Set a mission jack to the fuel tank.
    2. Remove the 4 bolts, 2 fuel tank bands and fuel tank.
    Fig 15: Removing Tank Bands And Fuel Tank
    G02898745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FUEL TANK MAIN TUBE SUB-ASSY 
    1. Remove the fuel tank main tube from the fuel tube clamp and bracket.
    Fig 16: Removing Fuel Tank Main Tube From Fuel Tube Clamp And Bracket
    G02898746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FUEL TUBE CLAMP NO. 4 
    1. Remove the bolt and fuel tank clamp.
    Fig 17: Removing Fuel Tank Clamp
    G02898747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FUEL TUBE BRACKET 
    1. Remove the fuel tube bracket from the fuel tank.
    Fig 18: Removing Fuel Tube Bracket From Fuel Tank
    G02898748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE 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 the 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 19: Pulling Out Fuel Emission Tube
    G02898749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 20: Identifying Connector Clip, Connector And Fuel Tube
    G02898750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE FUEL TUBE CLAMP NO. 2 
    1. Remove the fuel tube clamp from the fuel tank.
    Fig 21: Removing Fuel Tube Clamp From Fuel Tank
    G02898751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE CHECK VALVE PROTECTOR 
    1. Using a screwdriver, unlock the claw, and remove the check valve protector by turning it counter clockwise.
    Fig 22: Removing Check Valve Protector
    G02898752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE FUEL TANK INLET VALVE ASSY 
    1. Insert a clip remover between the fuel tank inlet valve and gasket, remove the fuel tank inlet valve by gradually pushing it upward.
    NOTE:
    • Work accurately to maintain the sealing performance of the fuel tank inlet valve, since it is made from resin. It is easy to damage by removing and installing forcibly.
    • Be sure to install a new fuel tank inlet valve and gasket.
    Fig 23: Removing Fuel Tank Inlet Valve Assy
    G02898753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE CHECK VALVE GASKET 
    1. Remove the gasket from the fuel tank inlet valve.
    Fig 24: Removing Gasket From Fuel Tank Inlet Valve
    G02898754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE FUEL TANK CUSHION NO.1 
    1. Remove the 7 fuel tank cushions from the fuel tank.
    Fig 25: Removing Fuel Tank Cushions From Fuel Tank
    G02898755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL FUEL TANK CUSHION NO.1 
    1. Install the 7 new fuel tank cushions to the fuel tank.
    Fig 26: Installing New Fuel Tank Cushions To Fuel Tank
    G02898756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL CHECK VALVE GASKET 
    1. Install a new gasket to the fuel tank.
    Fig 27: Installing New Gasket To Fuel Tank
    G02898757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL FUEL TANK INLET VALVE ASSY 
    1. Apply a light coat of oil around the fuel tank inlet valve as shown in the illustration, and insert it into the fuel tank without force.
    NOTE: Be careful not to drop the gasket into the fuel tank.
    Fig 28: Installing Fuel Tank Inlet Valve Assy
    G02898758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL FUEL EMISSION TUBE SUB-ASSY NO. 1 
    1. Push in the fuel tube connector 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.
  35. INSTALL FUEL TUBE CLAMP NO. 4 
    1. Install the fuel tube clamp with the bolt.

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

  36. INSTALL FUEL TANK ASSY 
    1. Set a mission jack to the fuel tank.
    2. Install the fuel tank and 2 fuel tank bands with the 4 bolts.

      Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

  37. CONNECT FUEL EMISSION TUBE SUB-ASSY NO. 1 
    1. Push in the fuel tube connector 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.
  38. CONNECT FUEL TANK MAIN TUBE SUB-ASSY 
    1. Push in the fuel tube connector to pipe until fuel tube connector, and install the fuel tube connector clip.
    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.
  39. INSTALL PARKING BRAKE CABLE ASSY NO. 3 
    1. Install the parking brake cable with the 2 bolts.

      Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) 

  40. INSTALL PARKING BRAKE CABLE ASSY NO. 2 
    1. Install the parking brake cable with the 2 bolts.

      Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) 

  41. INSTALL FUEL TANK PROTECTOR NO. 1 
    1. Install the fuel tank protector with the 5 bolts.

      Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) 

  42. INSTALL EXHAUST PIPE ASSY FRONT 
    1. Using vernier calipers, measure the free length of the compression spring.

      Free length: 

      Front side 43mm (1.6929 in.) 

      Rear side 40mm (1.5748 in.) 

    2. Using a hammer and wooden block, tap in a new gasket until its surface is flush with the exhaust manifold.
      NOTE:
      • Tap in the gasket in the correct direction.
      • Do not reuse the removed gasket.
      • Be sure not to push in the gasket by installing the exhaust pipe.
      Fig 29: Tapping New Gasket
      G02898759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new gasket on the exhaust pipe (rear side).
    4. Install the exhaust pipe with the 4 compression springs and 4 bolts.

      Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) 

    5. Install the 2 exhaust pipe supports.
    6. Connect the oxygen sensor connector.
    7. Install the font floor carpet with a clip.
    Fig 30: Installing New Gasket On Exhaust Pipe (Rear Side)
    G02898760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL FLOOR PANEL BRACE FRONT 
    1. Install the floor panel brace front with the 2 nuts.

      Torque: 30 N.m (302 kgf.cm, 22 ft.lbf) 

  44. INSTALL FUEL SUCTION TUBE SET GASKET (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  45. INSTALL FUEL PUMP ASSEMBLY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  46. INSTALL FUEL TANK VENT TUBE SET PLATE (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  47. CONNECT FUEL EMISSION TUBE SUB-ASSY NO. 1 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  48. CONNECT FUEL TANK MAIN TUBE SUB-ASSY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  49. CHECK FUEL LEAK (See  FUEL SYSTEM  ) 
  50. CHECK EXHAUST GAS LEAK 
  51. INSTALL REAR FLOOR SERVICE HOLE COVER (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  52. INSTALL BENCH TYPE REAR SEAT CUSHION ASSY (See  OVERHAUL (W/SEPARATE TYPE)  or  OVERHAUL (W/BENCH TYPE)  ) 
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