Yaris 2007

Removal & Installation

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  1. Remove the fuel pump module assembly.
  2.  
  3. Drain the fuel.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove front floor heat insulator no. 4. Remove the 2 nuts together with the insulator.
  8.  
  9. Remove fuel tank protector sub-assembly. Remove the bolt together with the clip.
  10.  
  11. Disconnect fuel tank main tube sub-assembly. Release the lock as shown in the illustration, then pull and remove the fuel tank main tube.
    NOTE
    Note the following:



    Remove any dirt and foreign matter from the clip before performing this work.
     
    Avoid any scratches or foreign matter on the parts when disconnecting them, as the quick connector has the O-ring that seals the plug.
     
    Perform this work by hand. Do not use any tools.
     
    Do not forcibly bend, twist or turn the nylon tube.
     
    Protect the disconnected parts by covering them with a plastic bag.
     
    If the connector and pipe are stuck, disconnect the nylon tube by turning it by hand to release them.

    Click image to see an enlarged view

    Fig. Release the lock as shown, then pull and remove the fuel tank main tube

     

  12.  
  13. Disconnect fuel tank breather hose. Release the lock as shown in the illustration, then pull and remove the fuel tank breather hose.
    NOTE
    Note the following:



    Remove any dirt and foreign matter from the clip before performing this work.
     
    Avoid any scratches or foreign matter on the parts when disconnecting them, as the quick connector has the O-ring that seals the plug.
     
    Perform this work by hand. Do not use any tools.
     
    Do not forcibly bend, twist or turn the nylon tube.
     
    Protect the disconnected parts by covering them with a plastic bag.
     
    If the connector and pipe are stuck, disconnect the nylon tube by turning it by hand to release them.

    Click image to see an enlarged view

    Fig. Disconnect fuel tank breather hose. Release the lock as shown

     

  14.  
  15. Loosen the clamp and disconnect the fuel tank filler pipe.
  16.  
  17. Remove fuel tank assembly:
    1. Remove the 4 bolts and remove the fuel tank.
    2.  
    3. Remove the fuel tank main tube from the fuel tank.

      Click image to see an enlarged view

      Fig. View of the fuel tank and components

    4.  

  18.  
  19. To install, reverse the removal procedure. Refer to the exploded illustration for torque values.
  20.  
  21. Check for fuel leakage:
    1. Connect the Techstream to the DLC3.
    2.  
    3. Turn the ignition switch to ON and turn the tester ON.
      NOTE
      Do not start the engine.

    4.  
    5. Select the following menu items: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
    6.  
    7. Check that there is no fuel leakage anywhere on the fuel system after doing maintenance.
    8.  

  22.  
  23. Check for engine oil leakage.
  24.  

 
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