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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 Tank >> Removal [08/2013 - ] >> Procedure

Removal [08/2013 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 

    Refer to REMOVAL [08/2013 - 08/2016] Refer to REMOVAL [08/2016 - ] 

  2. DRAIN FUEL 
  3. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst) 

    Refer to REMOVAL [08/2013 - ]

  4. REMOVE NO. 1 FUEL TANK PROTECTOR 
    1. Remove the 5 bolts and No. 1 fuel tank protector.
      GTY436883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. SEPARATE PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the 4 bolts and separate the No. 2 parking brake cable assembly and No. 3 parking brake cable assembly.
      GTY436881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
      GTY437635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Pull Out
      Pull Off
      NOTE:
      • Remove any dirt or foreign matter on the fuel tank vent hose sub-assembly before performing this work.
      • Do not allow any scratches or 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 fuel pipe.
      • Only 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. DISCONNECT FUEL TANK BREATHER TUBE 
    1. Disconnect the fuel tank breather tube.
      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.
        GTY445865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        *e Nylon Tube
        Push
        Pull Out
        Pull Off
        NOTE:
        • Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.
        • Be sure to disconnect the fuel tube connector by hand.
      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        NOTE:
        • Be sure to disconnect the fuel tube connector by hand.
        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.
        • Do not forcibly bend, twist or turn the nylon tube.
      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    2. Disengage the clamp to disconnect the fuel tank breather tube.
      GTY452395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank main tube sub-assembly.
      1. Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.
        GTY435900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Fuel Pipe
        Pull Out
        Pull Off
        NOTE:
        • Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.
        • Be sure to disconnect the fuel tube connector by hand.
      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        NOTE:
        • Be sure to disconnect the fuel tube connector by hand.
        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.
      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
  9. DISCONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Using a screwdriver, disengage the claw. Then remove the fuel tank filler pipe cover from the fuel tank to filler pipe hose.
      GTY437487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Loosen the clamp, then disconnect the fuel tank to filler pipe hose from the fuel tank assembly.
      GTY429026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FUEL TANK ASSEMBLY 
    1. Support the fuel tank assembly using an engine lifter.
      GTY436885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Using height adjustment attachments and plate lift attachments, place the fuel tank assembly horizontally.

    2. Remove the 4 bolts, No. 1 fuel tank band sub-assembly LH and No. 1 fuel tank band sub-assembly RH.
      GTY438595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Lower the engine lifter to remove the fuel tank assembly.
      NOTE:
      • Do not drop the fuel tank assembly.
      • When removing the fuel tank assembly, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.
  11. REMOVE FUEL TANK CUSHION 
    1. Remove the 2 No. 1 fuel tank cushions, No. 2 fuel tank cushion and No. 3 fuel tank cushion from the fuel tank assembly.
      GTY429573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion
      *3 No. 3 Fuel Tank Cushion
  12. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the fuel tank main tube sub-assembly from the fuel tank assembly.
      GTY436886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Remove the fuel tank vent hose sub-assembly from the fuel tank clamp.
      GTY453251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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