Toyota Celica 1986-1993 Repair Guide

Fuel Tank Assembly

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REMOVAL & INSTALLATION





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Fig. Fig. 1 Fuel tank components2S-E, 3S-FE and 3S-GE engines



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Fig. Fig. 2 Fuel tank components3S-GTE engine



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Fig. Fig. 3 Fuel tank components4A-FE and 5S-FE engines



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Fig. Fig. 4 Torquing flare nut type fittingCelica



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Fig. Fig. 5 Fuel line hose positioning to tubeCelica


CAUTION
To avoid personal injury, do not smoke or use any type of open flame when removing the fuel tank! Always use new gaskets on any fuel tank or fuel line component. During installation, make sure that the rubber protectors are installed with the fuel tank and make sure that all line or plug torque specification are observed. To reduce the amount of fuel that you will have to dispose of, use as much of the fuel as possible before draining the tank. On vehicles equipped with inflatable restraints or air bag systems, wait at least 30 seconds after disconnecting the battery cable before performing any other work. The backup power will keep the restraint system energized for a period of time after the battery is disconnected.

  1. Raise and safely support the vehicle. Disconnect the negative battery cable and properly relieve the fuel system pressure.
  2.  
  3. If equipped with a drain plug position a large capacity waste drain receptacle under the drain plug.
  4.  
  5. Remove the drain plug and gasket. Discard the gasket and purchase a new one.
  6.  
  7. If not equipped with a drain plug obtain an approved pumping device and drain fuel from the tank.
  8.  
  9. Remove the luggage compartment mat. Remove the cover over the tank sending unit and hose connections. Disconnect the gauge electrical harness and the vent, feed and fuel return hoses. Disconnect the fuel inlet filler neck.
  10.  
  11. With the aid of an assistant, support the tank and remove the tank strap bolts. Lower the tank and remove it from the vehicle.
  12.  

To install:

  1. Raise the tank and position on vehicle. Install the tank straps and tighten the bolts to 29 ft. lbs. (39 Nm).
  2.  
  3. Connect the fuel inlet filler neck, gauge electrical harness, vent hose and feed and fuel return hoses. Make sure all hose and electrical connections are secure.
  4.  


WARNING
Be careful not to twist or kink any of the hoses.

  1. Connect the negative battery cable and check for fuel leaks.
  2.  

SENDING UNIT REPLACEMENT




CAUTION
To avoid personal injury, do not smoke or use any type of open flame when removing the fuel tank! Always use new gaskets on any fuel tank or fuel line component. During installation, make sure that the rubber protectors are installed with the fuel tank and make sure that all line or plug torque specification are observed. To reduce the amount of fuel that you will have to dispose of, use as much of the fuel as possible before draining the tank. On vehicles equipped with inflatable restraints or air bag systems, wait at least 30 seconds after disconnecting the battery cable before performing any other work. The backup power will keep the restraint system energized for a period of time after the battery is disconnected.

2S-E, 3S-FE, 3S-GE and 3S-GTE Engines
  1. Raise and safely support the vehicle. Disconnect the negative battery cable and properly relieve the fuel system pressure.
  2.  
  3. If equipped with an access cover under the rear seat, do not drain the tank yet, since the tank may not have to be removed if there is enough clearance to remove the sender. If there is not enough clearance and if equipped with a drain plug, position a large capacity waste drain receptacle under the drain plug.
  4.  
  5. Remove the drain plug and gasket. Discard the gasket and purchase a new one.
  6.  
  7. If not equipped with a drain plug obtain an approved pumping device and drain fuel from the tank.
  8.  
  9. Remove the luggage compartment mat. Remove the cover over the tank sending unit and hose connections, if equipped. Disconnect the gauge electrical harness and the vent, feed and fuel return hoses. Disconnect the fuel inlet filler neck.
  10.  
  11. With the aid of an assistant, support the tank and remove the tank strap bolts. Lower the tank and remove it from the vehicle.
  12.  
  13. Remove the screws from the smaller retaining plate (the other larger one is the fuel pump) on the top of the tank and pull out the sending unit from the fuel tank. Discard the old gasket.
  14.  

To install:

  1. Install the sending unit into the fuel tank and secure in place. Replace the gasket prior to installation. Torque the retaining ring screws to 17 in. lbs. (2.0 Nm).
  2.  
  3. Raise the tank and position on vehicle. Install the tank straps and tighten the bolts to 29 ft. lbs. (39 Nm).
  4.  
  5. Connect the fuel inlet filler neck, gauge electrical harness, vent hose and feed and fuel return hoses. Make sure all hose and electrical connections are secure.
  6.  


WARNING
Be careful not to twist or kink any of the hoses.

  1. Connect the negative battery cable and check for fuel leaks.
  2.  

4A-FE and 5S-FE Engines

The sender on these engines is removed with the fuel pump assembly (See Fuel Pump).

 
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