G16E-GTS (FUEL): FUEL PUMP: REMOVAL; 2023 - 2025 MY GR Corolla [11/2022

Last Modified: 07-31-2024	6.11:8.1.0	Doc ID: RM1000000028FVU
Model Year Start: 2023	Model: GR Corolla	Prod Date Range: [11/2022 - ]
Title: G16E-GTS (FUEL): FUEL PUMP: REMOVAL; 2023 - 2025 MY GR Corolla [11/2022 - ]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during fuel pump removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Replacement of fuel pump	Inspection after repair	Poor idle, etc. Engine start function, etc.

CAUTION:

Never perform work on fuel system components near any possible ignition sources.
Vaporized fuel could ignite, resulting in a serious accident.

Do not perform work on fuel system components without first disconnecting the cable from the negative (-) battery terminal.
Sparks could cause vaporized fuel to ignite, resulting in a serious accident.

HINT:

When the cable is disconnected / reconnected to the battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when vehicle is driven

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Front Camera System	Drive the vehicle straight ahead at 35 km/h (22 mph) or more for 5 seconds or more.

Learning completes when vehicle is operated normally

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Power Door Lock Control System Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal.

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2. DISCHARGE FUEL SYSTEM PRESSURE

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3. REMOVE DECK BOARD ASSEMBLY

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4. REMOVE SPARE WHEEL CUSHION

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5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

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6. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY (w/ Rear Seat Assembly)

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7. REMOVE REAR NO. 1 FLOOR BOARD (w/o Rear Seat Assembly)

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8. REMOVE REAR NO. 1 FLOOR BOARD PANEL (w/o Rear Seat Assembly)

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9. REMOVE REAR FLOOR SERVICE HOLE COVER (for LH Side)

(a) Using a clip remover with its tip wrapped with protective tape, remove the rear floor service hole cover and butyl tape.

*a	Protective Tape

(b) Disconnect the 2 fuel suction pump and gauge tube assembly connectors.

10. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.

NOTICE:

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.

*1	Tube Joint Clip
*2	Fuel Tank Main Tube Sub-assembly
*3	Plate Sub-assembly
*a	Fuel Tube Joint
*b	Nylon Tube
*c	O-ring
	Pull off
	Pull off

(b) Disengage the clamp to disconnect the fuel tank main tube sub-assembly.

11. REMOVE NO. 1 FUEL TUBE CLAMP

(a) Disengage the claw to remove the No. 1 fuel tube clamp from the fuel pump gauge retainer.

12. REMOVE FUEL PUMP GAUGE RETAINER

(a) Remove the fuel pump gauge retainer.

(1) Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.

SST: 09808-14031

09808-01030

09808-01090

SST: 09808-01071

HINT:

Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.

*a	SST (Plate)
*b	SST (Bolt)
*c	SST (Claw)
*d	Insertion Point

(2) While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).

(3) Install SST (handle) and an extension bar to SST (plate).

SST: 09808-14031

09808-01010

*a	SST (Handle)
*b	SST (Plate)
*c	SST (Bolt)
*d	SST (Claw)
*e	Extension Bar

(4) Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing down on SST, rotate SST (handle) slowly to loosen the fuel pump gauge retainer.

NOTICE:

Do not use any tools other than specified as this may result in damage to the fuel pump gauge retainer or fuel tank sub-assembly.
Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.
Do not spin SST too fast or use an impact wrench as this may result in damage to components.
If SST comes off of the fuel pump gauge retainer, loosen SST (bolt) and reinstall SST.

(5) While pressing down on the fuel suction tube with pump and gauge assembly, remove the fuel pump gauge retainer.

13. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

(a) Disconnect the fuel return vent tube sub-assembly and remove the fuel suction tube with pump and gauge assembly from the fuel tank sub-assembly.

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NOTICE:

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

(b) Remove the fuel suction tube set gasket from the fuel tank sub-assembly.