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Toyota Corolla Repair Manual: Removal & installation and disassembly & reassembly

Toyota Corolla Repair Manual / Fuel / Fuel pump assy / Removal & installation and disassembly & reassembly

1. Remove bench type rear seat cushion assy

2. Remove rear floor service hole cover

  1. Remove the rear service hole cover.

  1. Disconnect the fuel pump and vapor pressure sensor connector.

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 subassy

  1. Remove the tube joint clip, and pull out the fuel tank main tube.

Notice

:

5. Disconnect fuel emission tube subassy

5. Disconnect fuel emission tube subassy no.1

  1. Pinch the fuel tube connector clip and then pull out the fuel emission tube.

Notice

:

6. Remove fuel tank vent tube set plate

6. Remove fuel tank vent tube set plate

  1. Remove the 8 bolts and fuel tank vent tube set plate.

7. Remove fuel pump assembly

7. Remove fuel pump assembly

  1. Pull out the fuel pump assembly.

Notice

:

8. Remove fuel suction tube set gasket

  1. Remove the gasket from the fuel pump assembly.

9 Remove fuel suction tube set gasket

  1. Using a screwdriver, disconnect the 5 snap claws from the claw holes, and remove the fuel suction support.

Notice

: do not damage the fuel suction support.

10. Remove fuel pump cushion rubber

  1. Remove the fuel pump cushion rubber.

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.

12. Remove fuel suction plate subassy

  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.

Notice

: do not damage the fuel suction plate.

13. Remove vapor pressure sensor assy

  1. Remove the tube joint clip, and pull out the vapor pressure sensor.

14. Remove fuel pump harness

  1. Remove the fuel pump harness from the fuel suction plate.

15. Remove fuel pump

  1. Pull out the fuel pump from the fuel filter.

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.

17. Remove fuel pressure regulator assy

  1. Pull out the fuel pressure regulator from the fuel filter.

18. Remove fuel pressure regulator oring

  1. Remove an oring from the fuel pressure regulator.

19. Install fuel pressure regulator oring

  1. Apply a light coat of gasoline to a new oring, and install it to the fuel pressure regulator.

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 oring, and install the fuel pump to the fuel filter.

22. Install vapor pressure sensor assy

  1. Install the vapor pressure sensor with the tube joint clip.

Notice

:

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.

Notice

:

25. Install fuel tank vent tube set plate

  1.  install the fuel tank vent tube set plate with the 8 bolts.

    Torque: 6.0 Nvm (61 kgfvcm, 53 in.Vlbf)

26. Connect fuel emission tube subassy no.1

  1.  push in the fuel emission tube to the pipe until fuel tube connector makes click sound.

Notice

:

27. Connect fuel tank main tube subassy

  1. connect the fuel tank main tube with the tube joint clip.

Notice

:

28. Check fuel leak

29. Install rear floor service hole cover

  1. Using the butyl tape, install the rear floor service hole cover.

30. Install bench type rear seat cushion assy

Components
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Fuel tank assy
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Other materials:

For vehicles equipped with catalytic converter
Caution: if large amount of unburned fuel flows into the converter, it may cause overheating and a fire hazard. To prevent this, observe the following precautions. Use only unleaded gasoline.  avoid prolonged idling. Avoid running the engine at idle speed for more than 20 minutes. ...

If a warning message or indicator is displayed (vehicles with a multi-information display)
If a warning is shown on the multi-information display, stay calm and perform the following actions: 1 Master warning light The master warning light also comes on or flashes in order to indicate that a message is currently being displayed on the multiinformation display. 2 Multi-information d ...

Inspection procedure
1 Check d squib circuit(airbag sensor assy center horn button assy) Disconnect the negative () terminal cable from the battery, and wait at least for 90 seconds.  disconnect the connectors between the horn button assy and the airbag sensor assy center.  for the black co ...

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