Corolla 2006-2007

Removal & Installation

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Specific to:

Toyota Corolla 2007-2008

  1. Disconnect battery negative terminal.
  2.  
  3. Removed fuel section with pump and gauge tube assembly.
  4.  
  5. Drain fuel
  6.  
  7. Remove front exhaust pipe assembly.
  8.  
  9. Remove front floor carpet.
  10.  
  11. Disconnect the heated oxygen sensor connector.
  12.  
  13. Remove the grommet, then pull the connector to the outside of the vehicle.
  14.  
  15. Remove 2 nuts and the floor panel brace front.
  16.  
  17. Remove the 4 bolts and 4 compression springs.
  18.  
  19. Remove the exhaust pipe front from the 2 exhaust pipe supports.
  20.  
  21. Remove the gasket from the exhaust manifold.
  22.  
  23. Remove the gasket from the exhaust pipe front.
  24.  
  25. Remove the 4 bolts, then remove the fuel tank protector.

    Click image to see an enlarged view

    Fig. Removing fuel tank protector

  26.  
  27. Remove the 2 bolts, then disconnect the parking brake cable.
  28.  
  29. Disconnect the fuel tank main tube.
    1. Pinch the tab of the retainer of the fuel tube connector to remove the lock claws and push it down as shown in the illustration below.
    2.  
    3. Pull the fuel tank main tube out of the pipe.

      Click image to see an enlarged view

      Fig. Removing fuel tank main tube



      Remove any dirt or foreign objects on the fuel tube connector before performing this work.
       
      Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
       
      Perform this work by hand. Do not use any tools.
       
      Do not forcibly bend, twist or turn the nylon tube.
       
      Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tank main tube.
       
      If the fuel tube connector and pipe are stuck, push and pull them to release.
       

    4.  

  30.  
  31. Disconnect the fuel tank breather tube.
    1. Remove the checker of the fuel tube connector from the pipe.
    2.  
    3. Pinch the retainer of the fuel tube connector, then pull the fuel tube connector out of the pipe.
      NOTE



      Click image to see an enlarged view

      Fig. Removing fuel tank breather tube



      Remove any dirt or foreign objects on the fuel tube connector before performing this work.
       
      Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
       
      Perform this work by hand. Do not use any tools.
       
      Do not forcibly bend, twist or turn the nylon tube.
       
      Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tank main tube.
       
      If the fuel tube connector and pipe are stuck, push and pull them to release.
       

    4.  

  32.  
  33. Disconnect the fuel tank vent hose.
    1. Pinch the tab of the retainer of the fuel tube connector to remove the lock claws and slide it as shown in the illustration below.
    2.  
    3. Pull the fuel tank vent hose out of the pipe.
      NOTE



      Click image to see an enlarged view

      Fig. Removing fuel tank vent hose



      Remove any dirt or foreign objects on the fuel tube connector before performing this work.
       
      Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
       
      Perform this work by hand. Do not use any tools.
       
      Do not forcibly bend, twist or turn the nylon tube.
       
      Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tank main tube.
       

    4.  

  34.  
  35. Using a screwdriver, unfasten the claw. Then remove the fuel tank filler pipe cover from the fuel tank filler pipe.
  36.  
  37. Loosen the hose clamp bolt, then disconnect the fuel tank filler pipe hose from the fuel tank.
  38.  
  39. Hold and lower the fuel tank using a transmission jack.
  40.  

To install:

  1. To install reverse removal procedure.
  2.  

Specific to:

Toyota Corolla 2003-2006

  1. Remove the rear seat cushion.
  2.  
  3. Remove the service hole cover.
  4.  
  5. Start the engine. After the engine has stopped on the its own, turn the ignition switch OFF .
  6.  
  7. Remove the fuel pump assembly. See Fuel Pump Removal and Installation.
  8.  
  9. Remove the fuel suction tube set gasket.
  10.  
  11. Remove any fuel remaining in the tank.
  12.  
  13. Under the vehicle, remove the floor panel brace.

    Click image to see an enlarged view

    Fig. Remove the floor panel brace-2003-2006 Corolla



    Click image to see an enlarged view

    Fig. Remove the front part of the exhaust system-2003-2006 Corolla

  14.  
  15. Remove the exhaust system from the manifold back to the muffler.
  16.  
  17. Using a clip remover, remove the clip and tear off the front floor carpet.

    Click image to see an enlarged view

    Fig. Remove the front floor carpet -2003-2006 Corolla

  18.  
  19. Remove the 5 bolts and remove the fuel tank protector.
  20.  
  21. Remove the parking brake cable clamps.
  22.  
  23. Clean away any dirt caked around the fuel tube connector. Pinch the fuel supply tube connector clip and disconnect the line.
    NOTE
    Be careful of the O-ring on the fuel tube. Do not use any tools to squeeze or separate the tubes, and do not bend or twist the nylon tube by force. After disconnecting, cover the tube ends with a vinyl bag.



    Click image to see an enlarged view

    Fig. Squeeze the clip to disconnect the fuel line

  24.  
  25. Disconnect the fuel tank filler pipe from the fuel tank.
  26.  
  27. Disconnect the fuel tank breather hose from the fuel tank.
  28.  
  29. To disconnect the fuel tank bent hose from the charcoal canister, first push the connector deep inside, then pinch it and pull the tube out.

    Click image to see an enlarged view

    Fig. Push in, then pinch at A to disengage the connector

  30.  
  31. Disconnect the valve to fuel filler pipe hose from the fuel tank inlet pipe.
  32.  
  33. Pinch the fuel tube connector clip and then pull out the fuel emission tube.
    NOTE
    Be careful of the O-ring on the fuel tube. Do not use any tools to squeeze or separate the tubes, and do not bend or twist the nylon tube by force. After disconnecting, cover the tube ends with a vinyl bag.



    Click image to see an enlarged view

    Fig. Fuel tube connector

  34.  
  35. Support the fuel tank with a transmission jack.
  36.  
  37. Remove the straps and remove the fuel tank.
  38.  

To install:

  1. Lift the tank into place with a mission jack. Install the bands and torque the bolts to 29 ft. lbs. (39 Nm).
  2.  
  3. Begin connecting the various tubes and hoses. Make sure they are all clean and the O-rings are in good condition. Push the connectors and listen for a -click- sound indicating the connection is secure. Pull gently to make sure the connector is firmly latched.
  4.  
  5. Install the parking brake cable clamps and torque the bolts to 48 inch lbs. (5.5 Nm).
  6.  
  7. Install the fuel tank protector and torque the bolts to 48 inch lbs. (5.5 Nm).
  8.  
  9. Install the exhaust system using new gaskets. Don-t forget to reconnect the oxygen sensor.
  10.  
  11. Install the front floor carpet.
  12.  
  13. Install the floor panel brace and toque the nuts to 22 ft. lbs. (30 Nm).
  14.  
  15. Install a new gasket and install the fuel pump assembly. Connect the lines and wires.
  16.  
  17. Add fuel to the tank and run the engine to check the system for leaks.
  18.  
  19. Install the pump access cover and rear seat.
  20.  

 
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