Fuel Tank Installation

Install new fuel tank cushions onto the fuel tank.

Install the fuel tank vent hose onto the fuel tank clamp.

Install the fuel tank main tube onto the fuel tank.

Set the fuel tank on a transmission jack.

Operate the transmission jack, then install the fuel tank into the vehicle.

Install the 2 No. 1 fuel tank bands with the 4 bolts.

Torque:

39 N*m{400 kgf*cm, 29 ft.*lbf}

Connect the fuel tank filler pipe to the fuel tank.

NOTICE:

Make sure that the hose clamp is facing in the correct direction when installing.

Engage the claw, then install the fuel tank filler pipe cover onto the fuel tank filler pipe.

Connect the fuel tank main tube.

1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank main tube to the pipe, then push the retainer up until the claws lock.
   

   NOTICE:

   1. Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
      
   2. After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling on the fuel tube connector and pipe.
      

Connect the breather tube fuel hose to the clamp.

Connect the breather tube fuel hose to the pipe.

1. Align the fuel hose connector with the pipe, then push the fuel hose connector in until the retainer makes a "click" sound to connect the fuel tank breather tube fuel hose to the pipe.
   

   NOTICE:

   1. Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
      
   2. After connecting the fuel tank breather tube, check that the fuel pump tube is securely connected by pulling on the fuel tube connector and pipe.
      

Connect the fuel tank vent hose.

1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank vent hose to the pipe.
   

2. Slide the retainer of the fuel tube connector to lock the claws as shown in the illustration.
   

   NOTICE:

   1. Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
      
   2. After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling on the fuel tube connector.
      

Install the fuel tank protector sub-assembly with the 4 bolts.

Torque:

5.5 N*m{56 kgf*cm, 49 in.*lbf}

Install the parking cables with the 4 bolts.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Install the fuel suction tube assembly with pump and gauge (COROLLA_ZRE142 RM0000022XU05ZX.html).

Connect the cable to the negative battery terminal.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Check fuel pump operation.

1. Connect the Techstream to the DLC3.
   

2. Turn the ignition switch ON and turn the Techstream on.
   

   NOTICE:

   Do not start the engine.

3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
   

4. Check for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing from the fuel tank can be heard. If no sounds can be heard, check the integration relay, fuel pump, ECM and wiring connectors.
   

Inspect for fuel leaks.

1. Check that there are no fuel leakage after performing maintenance anywhere on the fuel system. If there is a fuel leak, repair or replace parts as necessary.
   

Turn the ignition switch off.

Disconnect the Techstream from the DLC3.