| Last Modified: 07-31-2024 | 6.11:8.1.0 | Doc ID: RM1000000028FVV |
| Model Year Start: 2023 | Model: GR Corolla | Prod Date Range: [11/2022 - ] |
| Title: G16E-GTS (FUEL): FUEL PUMP: INSTALLATION; 2023 - 2025 MY GR Corolla [11/2022 - ] | ||
INSTALLATION
CAUTION / NOTICE / HINT
NOTICE:
Make sure to correctly assemble the fuel return vent tube sub-assembly as shown in the illustration. If assembled incorrectly, the fuel sender gauge assembly (No. 2 fuel sender gauge assembly) may catch on the fuel return vent tube sub-assembly resulting in incorrect operation of the fuel sender gauge assembly (No. 2 fuel sender gauge assembly) and an incorrect value being displayed on the fuel gauge.
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*1 |
Fuel Return Vent Tube Sub-assembly |
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Front of the Vehicle |
PROCEDURE
1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY
(a) Install a new fuel suction tube set gasket to the fuel tank sub-assembly.
(b) Connect the fuel return vent tube sub-assembly and set the fuel suction tube with pump and gauge assembly to the fuel tank sub-assembly.
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![2023 - 2025 MY GR Corolla [11/2022 - ]; G16E-GTS (FUEL): FUEL SYSTEM: PRECAUTION](/t3Portal/stylegraphics/info.gif)
NOTICE:
Be careful not to bend the arm of the fuel sender gauge assembly.
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(c) Align the protrusions of the fuel suction tube with pump and gauge assembly with the notches in the fuel tank sub-assembly. |
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2. INSTALL FUEL PUMP GAUGE RETAINER
(a) Install the fuel pump gauge retainer.
(1) While pressing down on the fuel suction tube with pump and gauge assembly, temporarily install the fuel pump gauge retainer.
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(2) 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. |
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(3) While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).
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(4) Install SST (handle) and an extension bar to SST (plate). SST: 09808-14031 09808-01010 |
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(5) Using SST, rotate the fuel pump gauge retainer so that the triangle mark on the fuel pump gauge retainer is aligned with the triangle mark on the fuel tank sub-assembly to install the fuel suction tube with pump and gauge assembly to the fuel tank sub-assembly.
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.
- Make sure that the fuel suction tube set gasket does not come off.
3. INSTALL NO. 1 FUEL TUBE CLAMP
(a) Engage the claw to install the No. 1 fuel tube clamp to the fuel pump gauge retainer.
4. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Engage the clamp to connect the fuel tank main tube sub-assembly.
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*1 |
Fuel Suction Plate Sub-assembly |
*2 |
Tube Joint Clip |
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*3 |
Fuel Tank Main Tube Sub-assembly |
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*a |
Fuel Tube Joint |
*b |
O-ring |
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*c |
Correct |
*d |
- |
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*e |
Collar |
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- |
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Insert |
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Insert |
(b) Push the fuel tube joint of the fuel tank main tube sub-assembly, and install the tube joint clip.
NOTICE:
- Check that there are no scratches or foreign matter around the connecting parts of the fuel tube joint and plug before performing this work.
- Check that the fuel tube joint is securely inserted to the end.
- Check that the tube joint clip is on the collar of the fuel tube joint.
- After installing the tube joint clip, check that the fuel tank main tube sub-assembly is securely connected by pulling on it.
5. INSTALL REAR FLOOR SERVICE HOLE COVER (for LH Side)
(a) Remove any remaining butyl tape from the rear floor service hole cover and vehicle body.
(b) Clean the installation surfaces of the rear floor service hole cover and vehicle body.
(c) Connect the 2 fuel suction tube with pump and gauge assembly connectors.
(d) Install the rear floor service hole cover with new butyl tape.
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
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7. INSTALL SPARE WHEEL CUSHION
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8. INSTALL DECK BOARD ASSEMBLY
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9. INSPECT FOR FUEL LEAK
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10. INSTALL REAR NO. 1 FLOOR BOARD PANEL (w/o Rear Seat Assembly)
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11. INSTALL REAR NO. 1 FLOOR BOARD (w/o Rear Seat Assembly)
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12. INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY (w/ Rear Seat Assembly)
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13. PERFORM INITIALIZATION
(a) Perform "Inspection After Repair" after replacing a port fuel injector assembly.
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14. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL
HINT:
When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.
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