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Home >> Toyota >> 2004 >> Matrix Base, 4WD >> Repair and Diagnosis >> Engine Mechanical >> Fuel System >> Engine Fuel System >> Fuel Tank ASSY (Ff) >> Components >> Removal & Installation
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Removal & Installation

  1. REMOVE SEPARATE TYPE REAR SEAT CUSHION ASSY (See  REMOVAL & INSTALLATION   ) 
  2. REMOVE REAR FLOOR SERVICE HOLE COVER (See  REMOVAL & INSTALLATION   ) 
  3. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT 
    1. Start the engine.
    2. After the engine has stopped on the its own, turn the ignition switch to lock.
  4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY (See  REMOVAL & INSTALLATION   ) 
  5. DISCONNECT FUEL EMISSION TUBE SUB-ASSY No. 1 (See  REMOVAL & INSTALLATION   ) 
  6. REMOVE FUEL TANK VENT TUBE SET PLATE (See  REMOVAL & INSTALLATION   ) 
  7. REMOVE FUEL PUMP ASSEMBLY (See  REMOVAL & INSTALLATION   ) 
  8. REMOVE FUEL SUCTION TUBE SET GASKET (See  REMOVAL & INSTALLATION   ) 
  9. DRAIN FUEL 
  10. REMOVE CONSOLE BOX ASSY REAR (2ZZ-GE ENGINE TYPE) 
    Fig 1: Removing Console Box
    G00922809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the console box insert.
    2. Remove the console box damper.
    3. Remove the 4 bolts.
    4. Disconnect the power point socket connector, and remove the console box.
  11. REMOVE FLOOR PANEL BRACE FRONT 
    Fig 2: Removing Floor Panel Brace Front
    G00922810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 nuts and floor panel brace front.
  12. REMOVE EXHAUST PIPE ASSY FRONT 
    1. Using a clip remover, remove the clip.
      Fig 3: Removing Clip Using Clip Remover
      G00922811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tear off the front floor carpet.
    3. 1ZZ-FE:
      1. Disconnect the oxygen sensor connector.
        Fig 4: Disconnecting Oxygen Sensor Connector
        G00922812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. 2ZZ-GE:
      1. Disconnect the 2 oxygen sensor connectors.
    5. Remove the 2 exhaust pipe supports.
    6. Remove the 4 bolts, 4 compression springs and exhaust pipe.
  13. REMOVE FUEL TANK PROTECTOR No. 1 
    Fig 5: Removing Fuel Tank Protector No. 1
    G00922813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 5 bolts and fuel tank protector.
  14. SEPARATE PARKING BRAKE CABLE ASSY No. 2 
    Fig 6: Separating Parking Brake Cable Assy No. 2
    G00922814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 installing bolts of the parking brake cable.
  15. SEPARATE PARKING BRAKE CABLE ASSY No. 3  
    Fig 7: Separating Parking Brake Cable Assy No. 3
    G00922815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 installing bolts of the parking brake cable.
  16. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY 
    Fig 8: Disconnecting Fuel Tank Main Tube Sub-Assy
    G00922816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pinch the fuel tube connector clip, and remove the fuel tube connector clip.
    2. Pull out the fuel tank main tube.
    NOTE:
    • Check if there is any dirt like mud around the fuel tube connector before this work and clean the dirt away.
    • Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.
    • Do not use any tool in this work.
    • Do not bend or twist the nylon tube by force.
    • After disconnecting, cover the fuel tube connector with a vinyl bag.
    • When the fuel tube connector and pipe are stuck, pinch the fuel tank main tube between fingers, and turn it carefully to free and then disconnect the fuel tank main tube.
    Fig 9: Disconnecting Fuel Tube Connector
    G00922817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT FUEL TANK INLET PIPE FUEL HOSE 
    Fig 10: Disconnecting Fuel Tank Inlet Filler Pipe Hose
    G00922818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the fuel tank inlet filler pipe hose from the fuel tank.
  18. DISCONNECT FUEL TANK BREATHER HOSE 
    Fig 11: Disconnecting Fuel Tank Breather Hose
    G00922819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the fuel tank breather hose from the fuel tank.
  19. DISCONNECT FUEL TANK VENT HOSE 
    Fig 12: Disconnecting Fuel Tank Vent Hose
    G00922820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the fuel tank bent hose from the charcoal canister.
      1. Push the connector deep inside.
      2. Pinch portion A.
      3. Pull out the connector.
  20. DISCONNECT VALVE TO FUEL FILLER PIPE HOSE 
    Fig 13: Disconnecting Valve To Fuel Filler Pipe Hose
    G00922821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the valve to fuel filler pipe hose from the fuel tank inlet pipe.
  21. DISCONNECT FUEL EMISSION TUBE SUB-ASSY No. 1 
    1. Pinch the fuel tube connector clip and then pull out the fuel emission tube.
    Fig 14: Disconnecting Fuel Emission Tube Sub-Assy No. 1
    G00922822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Check if there is any dirt like mud around the fuel tube connector before this work and clean the dirt away.
    • Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.
    • Do not use any tool in this work.
    • Do not bend or twist the nylon tube by force.
    • After disconnecting, cover the fuel tube connector with a vinyl bag.
    • When the fuel tube connector and pipe are stuck, pinch the fuel emission tube between fingers, and turn it carefully to free and then disconnect the fuel emission tube.
    Fig 15: Disconnecting Fuel Tube Connector
    G00922823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FUEL TANK ASSY 
    Fig 16: Removing Fuel Tank Assy
    G00922824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Set a mission jack to the fuel tank.
    2. Remove the 4 bolts, 2 fuel tank bands and fuel tank.
  23. REMOVE FUEL TANK MAIN TUBE SUB-ASSY 
    Fig 17: Removing Fuel Tank Main Tube Sub-Assy
    G00922825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the fuel tank main tube from the fuel tube clamp and bracket.
  24. REMOVE FUEL TUBE CLAMP No. 4 
    Fig 18: Removing Fuel Tank Clamp No. 4
    G00922826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the bolt and fuel tank clamp.
  25. REMOVE FUEL TUBE BRACKET 
    Fig 19: Removing Fuel Tube Bracket
    G00922827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the fuel tube bracket from the fuel tank.
  26. REMOVE FUEL EMISSION TUBE SUB-ASSY No. 1 
    Fig 20: Removing Fuel Emission Tube Sub-Assy No. 1
    G00922828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pinch the fuel tube connector clip and then pull out the fuel emission tube.
    NOTE:
    • Check if there is any dirt like mud around the fuel tube connector before this work and clean the dirt away.
    • Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.
    • Do not use any tool in this work.
    • Do not bend or twist the nylon tube by force.
    • After disconnecting, cover the fuel tube connector with a vinyl bag.
      Fig 21: Disconnecting Fuel Tube Connector
      G00922829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • When the fuel tube connector and pipe are stuck, pinch the fuel emission tube between fingers, and turn it carefully to free and then disconnect the fuel emission tube.
  27. REMOVE FUEL TUBE CLAMP No. 2 
    Fig 22: Removing Fuel Tube Clamp No. 2
    G00922830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the fuel tube clamp from the fuel tank.
  28. REMOVE CHECK VALVE PROTECTOR 
    1. Using a screwdriver, unlock the claw, and remove the check valve protector by turning it counter clockwise.
    Fig 23: Unlocking Claw Using Screwdriver
    G00922831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE FUEL TANK INLET VALVE ASSY 
    Fig 24: Removing Fuel Tank Inlet Valve Assy
    G00922832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Insert a clip remover between the fuel tank inlet valve and gasket, remove the fuel tank inlet valve by gradually pushing it upward.
    NOTE:
    • Work accurately to maintain the sealing performance of the fuel tank inlet valve, since it is made from resin. It is easy to damage by removing and installing forcibly. 
    • Be sure to install a new fuel tank inlet valve and gasket.
  30. REMOVE CHECK VALVE GASKET 
    Fig 25: Removing Check Valve Gasket
    G00922833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the gasket from the fuel tank inlet valve.
  31. REMOVE FUEL TANK CUSHION No. 1 
    Fig 26: Removing Fuel Tank Cushion No. 1
    G00922834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 7 fuel tank cushions from the fuel tank.
  32. INSTALL FUEL TANK CUSHION No. 1 
    Fig 27: Installing Fuel Tank Cushion No. 1
    G00922835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 7 new fuel tank cushions to the fuel tank.
  33. INSTALL CHECK VALVE GASKET 
    Fig 28: Installing Check Valve Gasket
    G00922836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install a new gasket to the fuel tank.
  34. INSTALL FUEL TANK INLET VALVE ASSY 
    1. Apply a light coat of oil around the fuel tank inlet valve as shown in Fig 29 , and insert it into the fuel tank without force.
      Fig 29: Applying Light Coat Of Oil Around Fuel Tank Inlet Valve
      G00922837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Be careful not to drop the gasket into the fuel tank.
  35. INSTALL FUEL EMISSION TUBE SUB-ASSY No. 1 
    1. Push in the fuel tube connector to the pipe until fuel tube connector makes "click" sound.
    NOTE:
    • Check if there is any damage or foreign objects on the connected part.
    • After connecting, check if the pipe and fuel tube connector are securely connected by pulling them.
  36. INSTALL FUEL TUBE CLAMP No. 4 
    1. Install the fuel tube clamp with the bolt.
      1. Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 
  37. INSTALL FUEL TANK ASSY 
    1. Set a mission jack to the fuel tank.
    2. Install the fuel tank and 2 fuel tank bands with the 4 bolts.
      1. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 
  38. CONNECT FUEL EMISSION TUBE SUB-ASSY No. 1 
    1. Push in the fuel tube connector to the pipe until fuel tube connector makes "click" sound.
    NOTE:
    • Check if there is any damage or foreign objects on the connected part.
    • After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
  39. CONNECT FUEL TANK MAIN TUBE SUB-ASSY 
    1. Push in the fuel tube connector to pipe until fuel tube connector, and install the fuel tube connector clip.
    NOTE:
    • Check if there is any damage or foreign objects on the connected part.
    • After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
  40. INSTALL PARKING BRAKE CABLE ASSY No. 3 
    1. Install the parking brake cable with the 2 bolts.
      1. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 
  41. INSTALL PARKING BRAKE CABLE ASSY No. 2 
    1. Install the parking brake cable with the 2 bolts.
      1. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 
  42. INSTALL FUEL TANK PROTECTOR No. 1 
    1. Install the fuel tank protector with the 5 bolts.
      1. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 
  43. INSTALL EXHAUST PIPE ASSY FRONT 
    1. Using vernier calipers, measure the free length of the compression spring.
      1. Free length: 
        1. Front side 43mm (1.6929 in.) 
        2. Rear side 40mm (1.5748 in.) 
    2. Using a hammer and wooden block, tap in a new gasket until its surface is flush with the exhaust manifold.
      Fig 30: Taping In New Gasket Using Hammer & Wooden Block
      G00922838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Tap in the gasket in the correct direction.
      • Do not reuse the removed gasket.
      • Be sure not to push in the gasket by installing the exhaust pipe.
    3. Install a new gasket on the exhaust pipe (rear side).
      Fig 31: Installing New Gasket On Exhaust Pipe
      G00922839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the exhaust pipe with the 4 compression springs and 4 bolts.
      1. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) 
    5. Install the 2 exhaust pipe supports.
    6. 1ZZ-FE:
      1. Connect the oxygen sensor connector.
    7. 2ZZ-GE:
      1. Connect the 2 oxygen sensor connectors.
    8. Install the front floor carpet with a clip.
  44. INSTALL FLOOR PANEL BRACE FRONT 
    1. Install the floor panel brace front with the 2 nuts.
      1. Torque: 30 N.m (302 kgf.cm, 22 ft.lbf) 
  45. INSTALL FUEL SUCTION TUBE SET GASKET (See  REMOVAL & INSTALLATION   ) 
  46. INSTALL FUEL PUMP ASSEMBLY (See  REMOVAL & INSTALLATION   ) 
  47. INSTALL FUEL TANK VENT TUBE SET PLATE (See  REMOVAL & INSTALLATION   ) 
  48. CONNECT FUEL EMISSION TUBE SUB-ASSY No. 1 (See  REMOVAL & INSTALLATION   ) 
  49. CONNECT FUEL TANK MAIN TUBE SUB-ASSY (See  REMOVAL & INSTALLATION   ) 
  50. CHECK FUEL LEAK (See   ON-VEHICLE INSPECTION   ) 
  51. CHECK EXHAUST GAS LEAK 
  52. INSTALL REAR FLOOR SERVICE HOLE COVER (See  REMOVAL & INSTALLATION   ) 
  53. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSY (See  REMOVAL & INSTALLATION   ) 
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