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

Last Modified: 07-31-2024	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
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
Gas leak from exhaust system is repaired	Inspection after repair	Poor idle, etc. Engine start function, etc.
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
Tire	ECU Data Initialization (When performing tire replacement after RoB code X2104 is output)	Active Torque Split AWD System

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. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

Click here

2. REMOVE FUEL TANK VENT TUBE ASSEMBLY

Click here

3. DRAIN FUEL

4. REMOVE TAIL EXHAUST PIPE ASSEMBLY

Click here

5. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY

Click here

6. REMOVE FRONT FLOOR COVER RH

Click here

7. REMOVE FRONT FLOOR COVER LH

Click here

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

13. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

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

Click here

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

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.

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.