Toyota Corolla 1988-1997 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



See Figures 1 and 2



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Fig. Fig. 1: Exploded view of the fuel tank-1988-92 models



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Fig. Fig. 2: Exploded view of the fuel tank-1993-97 models

Before removing fuel system parts, clean them with a spray-type engine cleaner. Follow the instructions on the cleaner. Do not soak fuel system parts in liquid cleaning solvent. Refer to illustration of fuel tank and fuel pump assembly before starting this service repair.


CAUTION
The fuel injection system is under pressure. Release pressure slowly and contain spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.

  1. Disconnect the negative battery cable. Relieve the fuel pressure. Remove the filler cap. Using a siphon or pump, drain the fuel from the tank and store it in a proper metal container with a tight cap. If equipped with a drain plug drain the fuel tank by removing the drain plug.
  2.  
  3. Remove the fuel tank pipe protector.
  4.  
  5. On the 1993-97 models, remove the rear seat cushion to gain access to the electrical wiring.
  6.  
  7. On all models, disconnect the fuel pump and sending unit wiring at the connector.
  8.  
  9. Raise the vehicle and safely support it on jackstands.
  10.  
  11. Loosen the clamp and remove the filler neck assembly and overflow pipe assembly from the tank.
  12.  
  13. Remove the supply hose from the tank. Wrap a rag around the fitting to collect escaping fuel. Disconnect the breather hose or vent tube from the tank, again using a rag to control spillage.
  14.  
  15. Cover or plug the end of each disconnected line to keep dirt out and fuel in.
  16.  
  17. Support the fuel tank with a floor jack or transmission jack. Use a broad piece of wood to distribute the load. Be careful not to deform the bottom of the tank.
  18.  
  19. Remove the fuel tank support strap bolts.
  20.  
  21. Swing the straps away from the tank and lower the jack. Balance the tank with your other hand or have a helper assist you. The tank is bulky and may have some fuel left in it. If its balance changes suddenly, the tank may fall.
  22.  
  23. Remove the fuel filler pipe extension, the vent pipe assembly, fuel pump and or the sending unit assembly. Keep these items in a clean, protected area away from the car.
  24.  

On the 1988-92 models, the fuel pump and fuel sender gauge are two different assemblies. On the 1993-97 models, the fuel pump and fuel sender gauge are one unit.

  1. While the tank is out and disassembled, inspect it for any signs of rust, leakage or metal damage. If any problem is found, replace the fuel tank. Clean the inside of the tank with water and a light detergent and rinse the tank thoroughly several times.
  2.  
  3. Inspect all of the lines, hoses and fittings for any sign of corrosion, wear or damage to the surfaces. Check the pump outlet hose and the filter for restrictions.
  4.  
  5. When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration.
  6.  
  7. Connect the vent pipe assembly and the filler pipe extension to the fuel tank. Always use new hose clamps as necessary.
  8.  
  9. Install the fuel pump and bracket assembly into the tank with a NEW gasket and tighten retaining bolts to 30 inch lbs. (40 Nm).
  10.  
  11. Install the fuel sending unit assembly into the tank with a NEW gasket and tighten retaining bolts to 30 inch lbs. (40 Nm).
  12.  

Tighten the vent or breather tube screw to 17 inch lbs. (23 Nm) and all other attaching screws to 30 inch lbs. (40 Nm).

  1. Place the fuel tank on the jack and elevate it into place within the car. Attach the straps and install the strap bolts, tightening them to EVENLY 29 ft. lbs. (39 Nm).
  2.  

Make sure that fuel tank cushions are installed in the correct location before installing the fuel tank to the vehicle. The fuel tank cushions prevent vibration and noise during vehicle operation.

  1. Connect the breather hose or vent to the tank pipe, the return hose to the tank pipe and the supply hose to its tank pipe. tighten the supply hose fitting to 21 ft. lbs. (28 Nm).
  2.  
  3. Connect the filler neck and overflow pipe to the vehicle. Make sure the clamps are properly seated and secure.
  4.  
  5. Lower the vehicle to the ground.
  6.  
  7. Connect the pump and sending unit electrical connectors to the harness.
  8.  
  9. Install the rear seat cushion.
  10.  
  11. Using a funnel, pour the fuel that was drained from its container into the fuel filler.
  12.  
  13. Install the fuel filler cap.
  14.  
  15. Start the engine and check carefully for any sign of leakage around the tank and lines.
  16.  

 
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