Toyota Tercel 1984-1994 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



See Figures 1, 2, 3 and 4

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.


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. On fuel injected engines, properly relieve the fuel system pressure.
  2.  
  3. Remove the filler cap.
  4.  
  5. Using a siphon or pump, drain the fuel from the tank and store it in a proper metal container with a tight cap.
  6.  
  7. On 1991-1994 models, remove the rear seat cushion and service hole cover to gain access to the electrical wiring.
  8.  
  9. Unplug the connector(s) for the fuel pump and/or sending unit.
  10.  
  11. Raise the vehicle and safely support it on jackstands.
  12.  
  13. Loosen the clamp and remove the filler neck and overflow pipe from the tank.
  14.  
  15. Remove the supply hose from the tank. Wrap a rag around the fitting to collect escaping fuel. Disconnect the breather hose from the tank, again using a rag to control spillage.
  16.  
  17. Cover or plug the end of each disconnected line to keep dirt out and fuel in.
  18.  
  19. 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.
  20.  
  21. Remove the fuel tank support strap bolts.
  22.  
  23. 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.
  24.  

The fuel tank will release strong fuel vapors while it is removed from the vehicle. Be sure to store it in a safe, well ventilated area.

  1. Remove the fuel filler pipe extension, the breather pipe assembly and the sending unit assembly. Keep these items in a clean, protected area away from the car.
  2.  

To install:
  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 tank.
  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 breather pipe assembly and the filler pipe extension.
  8.  
  9. 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 29 ft. lbs. (39 Nm).
  10.  
  11. Connect the breather, return and supply hoses to the tank.
  12.  
  13. Connect the filler neck and overflow pipe to the tank. Make sure the clamps are properly seated and secure.
  14.  
  15. Lower the vehicle to the ground.
  16.  
  17. Connect the pump and/or sending unit electrical connector(s) to the harness.
  18.  
  19. Install the rear seat cushion and service hole cover, if applicable.
  20.  
  21. Using a funnel, pour the fuel that was drained from its container into the fuel filler.
  22.  
  23. Install the fuel filler cap.
  24.  
  25. Start the engine and check carefully for any sign of leakage around the tank and lines.
  26.  



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Fig. Fig. 1: Fuel tank and components on 1984-1986 sedans and all wagons



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Fig. Fig. 2: Fuel tank and components on 1987-1990 sedans equipped with 3E engines



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Fig. Fig. 3: Fuel tank and components on 1990 models equipped with fuel injected engines



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Fig. Fig. 4: Fuel tank and components on 1991-1994 models

 
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