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Home >> Toyota >> 2016 >> Corolla S, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 7 (Fuel System (2ZR-FAE) (Service Information) (Model Code: ZRE172)) >> Fuel Pump >> Removal [08/2016 - ] >> Procedure

Removal [08/2016 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Refer to PRECAUTION [08/2016 - ]

  2. REMOVE REAR SEAT CUSHION ASSEMBLY 
  3. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the rear floor service hole cover and butyl tape.
      GTY455065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel pump connector.
  4. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [08/2016 - ]

  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [08/2016 - 08/2017] Refer to INITIALIZATION [08/2017 - ]

  6. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Pull out the retainer to disengage the lock claws and pull off the fuel tank vent hose sub-assembly.
      GTY441585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Pull out
      Pull off
      NOTE:
      • Remove any foreign matter on the fuel tank vent hose sub-assembly before performing this work.
      • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tank vent hose sub-assembly has an O-ring that seals the pipe (fuel pipe).
      • Be sure to disconnect the fuel tank vent hose sub-assembly by hand.
      • Do not forcibly bend, twist or turn the fuel tank vent hose sub-assembly.
  7. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.
      GTY445968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Suction Plate Sub-assembly
      *2 Tube Joint Clip
      *a Fuel Tube Joint
      *b O-ring
      *c Nylon Tube
      Pull off
      Pull off
      NOTE:
      • Remove any foreign matter on the fuel tube joint before performing this work.
      • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
      • Be sure to disconnect the fuel tube joint by hand.
      • Do not bend, twist, pinch or kink the nylon tube.
      • Cover the disconnected fuel tube joint with a plastic bag to prevent damage and contamination.
      • If the fuel tube joint and fuel suction plate sub-assembly are stuck, push and pull to release them.
  8. REMOVE FUEL PUMP GAUGE RETAINER 
    NOTE:

    Before performing these procedures, first cover the connector and tube joint of the fuel suction tube assembly with vinyl tape and then clean any dirt and foreign matter in order to prevent contamination of the fuel system.

    1. Copy the start of threads mark and fully tightened marks from the fuel tank assembly to the vehicle body in order to record their locations.
      GTY451598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Copy of Fully Tightened Mark
      *b Copy of Start of Threads Mark
      *c Fully Tightened Mark on Fuel Tank Assembly
      *d Start of Threads Mark on Fuel Tank Assembly
    2. Place paint marks on the fuel suction tube with pump and gauge assembly and vehicle body as shown in the illustration.
      NOTE:
      • The fuel suction tube with pump and gauge assembly has a protrusion that engages with the notch on the fuel tank assembly to ensure correct alignment and to prevent the fuel suction tube with pump and gauge assembly from turning during installation and removal of the fuel pump gauge retainer.
      • If the fuel pump gauge retainer is turned with the fuel suction tube with pump and gauge assembly misaligned, the fuel suction tube with pump and gauge assembly will turn with the fuel pump gauge retainer and may be damaged.
      • The paint marks are used to ensure that the fuel suction tube with pump and gauge assembly does not turn with the fuel pump gauge retainer.
      GTY728404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      Front
    3. Install SST to the fuel pump gauge retainer.
      1. Set 4 SST (claw set) to the fuel pump gauge retainer.
        GTY706843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw Set)
        *b Protrusion
        *c Notch
        *d Do not install SST (Claw Set)
        • SST: 09808-14031 
          1. 09808-01080
          2. 09808-01090
          3. 09808-01100
        NOTE:
        • Align the notch of SST (claw set) with the protrusion of the fuel pump gauge retainer.
        • Do not install SST (claw set) to the start of threads location of the fuel pump gauge retainer.
      2. Push SST (claw set) against the fuel pump gauge retainer and tighten SST (bolt).
        GTY702309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Fuel Pump Gauge Retainer
        *a SST (Claw Set)
        *b Hook
        Push
        SST (Bolt)
      3. Temporarily install SST (plate) to SST (claw set) with 4 SST (bolt).
        GTY738040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Plate)
        *b SST (Claw Set)
        SST (Bolt)
        • SST: 09808-14031 
          1. 09808-01030
          2. 09808-01090
      4. Adjust the position of SST (claw set) so that the hole in SST (plate) for installing SST (handle) is in the center of the fuel pump gauge retainer.
        GTY740043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Center Point of Fuel Pump Gauge Retainer
        *b SST (Plate)
        Front
      5. Press SST (claw set) against the rib of the fuel pump gauge retainer and tighten SST (bolt).
        GTY689786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Fuel Pump Gauge Retainer
        *a SST (Plate)
        *b SST (Claw Set)
        *c SST (Bolt)
        Press
      6. Install SST (handle) to SST (plate).
        • SST: 09808-14031 
          1. 09808-01010
          2. 09808-01020
    4. Slowly loosen the fuel pump gauge retainer by approximately 90°.
      GTY696703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Plate)
      *b SST (Handle)
      Loosen
      NOTE:

      Do not spin SST too fast or use an impact wrench as this may result in damage to components.

    5. While one person loosens the fuel pump gauge retainer, have another person press down the rising fuel suction tube with pump and gauge assembly, securely insert the protrusion of the fuel suction tube with pump and gauge assembly into the groove of the fuel tank assembly, and then remove the fuel pump gauge retainer while making sure that the fuel suction tube with pump and gauge assembly is properly aligned.
      GTY703501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Plate) *b SST (Handle)
      *c One Person in Charge of Loosening *d One Person in Charge of Pressing Down
      *e Paint Mark - -
      NOTE:
      • The fuel suction tube with pump and gauge assembly is pressed against the underside of the fuel tank assembly by a spring, and the constant upward pressure applied by this spring causes the fuel suction tube with pump and gauge assembly to rise up.
      • If the fuel pump gauge retainer is turned while the fuel suction tube with pump and gauge assembly and fuel tank assembly are not correctly aligned, the fuel suction tube with pump and gauge assembly will move with the fuel pump gauge retainer, and the fuel suction tube with pump and gauge assembly and fuel tank assembly may both be damaged.
      • Do not turn the fuel pump gauge retainer if the paint marks become misaligned.
  9. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 
    1. Remove the fuel suction tube with pump and gauge assembly from the fuel tank assembly.
      NOTE:

      Be careful not to bend the arm of the fuel sender gauge assembly.

    2. Remove the fuel suction tube set gasket from the fuel tank assembly.
      GTY438680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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