Last Modified: 05-13-2024 6.11:8.1.0 Doc ID: RM1000000028IQE
Model Year Start: 2023 Model: GR Corolla Prod Date Range: [11/2022 -           ]
Title: G16E-GTS (FUEL): FUEL TANK: 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 tank sub-assembly 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 4WD linear solenoid (electro magnetic control coupling sub-assembly)

ECU Data Write (When replacing 4WD linear solenoid (electro magnetic control coupling sub-assembly))

Active Torque Split AWD System

2023 - 2025 MY Corolla Corolla Hatchback GR Corolla [09/2022 -        ]; GF1A (TRANSFER / 4WD / AWD): ACTIVE TORQUE SPLIT AWD SYSTEM: CALIBRATION

Gas leak from exhaust system is repaired

Inspection after repair

  • Poor idle, etc.
  • Engine start function, etc.

2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

Rear wheel alignment adjustment

  • Perform "Reset Memory"
  • Perform "Calibration"
  • VSC is disabled or malfunctions
  • DTCs are output
  • Slip indicator light illuminates
  • ABS warning light illuminates

2023 - 2025 MY Corolla Corolla Hatchback GR Corolla [11/2022 -        ]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for Gasoline Model with Electric Parking Brake System): UTILITY

Tire

ECU Data Initialization (When performing tire replacement after RoB code X2104 is output)

Active Torque Split AWD System

2023 - 2025 MY Corolla Corolla Hatchback GR Corolla [09/2022 -        ]; GF1A (TRANSFER / 4WD / AWD): ACTIVE TORQUE SPLIT AWD SYSTEM: CALIBRATION

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.

NOTICE:

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click here 2019 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [06/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

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.

2023 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [11/2022 -        ]; ADVANCED DRIVER ASSISTANCE SYSTEM: FRONT CAMERA SYSTEM: INITIALIZATION

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.

2023 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [11/2022 -        ]; DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: INITIALIZATION

PROCEDURE

1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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

2. REMOVE FUEL TANK VENT TUBE ASSEMBLY

Click here 2023 - 2025 MY GR Corolla [11/2022 -        ]; G16E-GTS (FUEL): FUEL SENDER GAUGE ASSEMBLY: REMOVAL+

3. DRAIN FUEL

4. REMOVE TAIL EXHAUST PIPE ASSEMBLY

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (INTAKE / EXHAUST): EXHAUST PIPE: REMOVAL

5. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY

Click here 2023 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [09/2022 -        ]; AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY: REMOVAL

6. REMOVE FRONT FLOOR COVER RH

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (INTAKE / EXHAUST): EXHAUST PIPE: REMOVAL+

7. REMOVE FRONT FLOOR COVER LH

Click here 2023 - 2025 MY GR Corolla [09/2022 -        ]; G16E-GTS (INTAKE / EXHAUST): EXHAUST PIPE: REMOVAL+

8. REMOVE REAR FLOOR SIDE MEMBER COVER RH

(a) Remove the 2 clips (A), 2 bolts (B) and 2 screws (C).

(b) Turn the clip (D) and remove the rear floor side member cover RH from the vehicle body.

NOTICE:

If the clip is not turned when the rear floor side member cover RH is removed, the rear floor side member cover RH or stud bolt may be damaged.

HINT:

Do not remove the clip from the rear floor side member cover RH.

9. REMOVE REAR FLOOR SIDE MEMBER COVER LH

(a) Remove the 2 clips (A), 2 bolts (B) and 2 screws (C).

(b) Turn the clip (D) and remove the rear floor side member cover LH from the vehicle body.

NOTICE:

If the clip is not turned when the rear floor side member cover LH is removed, the rear floor side member cover LH or stud bolt may be damaged.

HINT:

Do not remove the clip from the rear floor side member cover LH.

10. REMOVE NO. 2 FUEL TANK PROTECTOR

(a) Remove the nut from No. 1 fuel tank band sub-assembly RH.

(b) Remove the 4 clips and No. 2 fuel tank protector from the fuel tank sub-assembly.

11. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

(a) Remove the 4 clips and No. 1 fuel tank protector sub-assembly.

12. DISCONNECT FUEL CUT-OFF TUBE

(a) Disconnect the fuel cut-off tube from the fuel tank vent hose sub-assembly.

Click here 2023 - 2025 MY GR Corolla [11/2022 -        ]; G16E-GTS (FUEL): FUEL SYSTEM: PRECAUTION

13. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Remove the fuel tank main tube sub-assembly from the fuel pipe.

Click here 2023 - 2025 MY GR Corolla [11/2022 -        ]; G16E-GTS (FUEL): FUEL SYSTEM: PRECAUTION

14. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

(a) Loosen the hose clamp to disconnect the fuel tank to filler pipe hose from the fuel tank sub-assembly.

15. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY

(a) Disconnect the fuel tank breather tube sub-assembly to the fuel tank filler pipe sub-assembly.

Click here 2023 - 2025 MY GR Corolla [11/2022 -        ]; G16E-GTS (FUEL): FUEL SYSTEM: PRECAUTION

16. REMOVE FUEL TANK SUB-ASSEMBLY

CAUTION:

The fuel tank sub-assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank sub-assembly may fall off the engine lifter.

(a) Support fuel tank sub-assembly using an engine lifter.

HINT:

Using height adjustment attachments and plate lift attachments, keep the fuel tank sub-assembly horizontal.

(b) Remove the 4 bolts, No. 1 fuel tank band sub-assembly LH and No. 1 fuel tank band sub-assembly RH.

(c) Lower the engine lifter to remove the fuel tank sub-assembly.

NOTICE:

  • Be careful not to drop the fuel tank sub-assembly.
  • When removing the fuel tank sub-assembly, tilt it slightly to prevent it from interfering with the surrounding parts.

17. REMOVE FUEL RETURN VENT TUBE SUB-ASSEMBLY

(a) Remove the fuel return vent tube sub-assembly from the fuel tank sub-assembly.

18. REMOVE NO. 6 FUEL TANK CUSHION

(a) Remove the 3 No. 6 fuel tank cushions from the fuel tank sub-assembly.