Toyota Corolla Cross: Removal

REMOVAL

CAUTION / NOTICE / HINT

Procedure		Part Name Code
1	PRECAUTION	-		-	-
2	DISCHARGE FUEL SYSTEM PRESSURE	-		-	-
3	DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL	-	-	-	-
4	REAR SEAT ASSEMBLY	-	-	-	-
5	REAR FLOOR SERVICE HOLE COVER	58325M	-	-	-
6	FUEL TANK VENT HOSE SUB-ASSEMBLY	77404	-	-	-
7	FUEL TANK MAIN TUBE SUB-ASSEMBLY	77209F		-	-
8	NO. 1 FUEL TUBE CLAMP	77285D	-	-	-
9	FUEL PUMP GAUGE RETAINER	77144		-	-
10	FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY	77020A		-	-

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during fuel pump removal/installation are shown below.

CAUTION:

• Never perform work on fuel system components near any possible ignition sources.
• Vaporized fuel could ignite, resulting in a serious accident.

• Do not perform work on fuel system components without first disconnecting the cable from the negative (-) auxiliary battery terminal.
• Sparks could cause vaporized fuel to ignite, resulting in a serious accident.

NOTICE:

After the ignition switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 120 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal.

HINT:

When the cable is disconnected/reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

• Learning completes when vehicle is driven.

  Effect/Inoperative Function When Necessary Procedures are not Performed	Necessary Procedures	Link
  Front camera system	Drive the vehicle straight ahead at 15 km/h (10 mph) or more for 1 second or more.
  Stop and start system	Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)

• Learning completes when vehicle is operated normally

  Effect/Inoperative Function When Necessary Procedures are not Performed	Necessary Procedures	Link
  Power door lock control system Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.
  Power back door system	Fully close the back door by hand. HINT: Initialization is not necessary if the above procedures are performed while the back door is closed.
  Air conditioning system	After the ignition switch is turned to ON, the servo motor standard position is recognized.	-

PROCEDURE

1. PRECAUTION

NOTICE: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Click here

2. DISCHARGE FUEL SYSTEM PRESSURE

Click here

3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

Click here

4. REMOVE REAR SEAT ASSEMBLY

Click here

5. REMOVE REAR FLOOR SERVICE HOLE COVER

6. INSTALL FUEL TANK VENT HOSE SUB-ASSEMBLY

(1) Disconnect the fuel tank vent hose sub-assembly from the fuel suction tube with pump and gauge assembly.

Click here

7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

*1	Fuel Suction Plate Sub-assembly	*2	Tube Joint Clip
*3	Fuel Tank Main Tube Sub-assembly	-	-
*a	Fuel Tube Joint	*b	O-ring
*c	Nylon Tube	-	-
	Pull off		Pull off

(1) Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.

NOTICE:

• Remove any foreign matter on the fuel tube joint before performing this work.
• Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
• Be sure to disconnect the fuel tube joint by hand.
• Do not bend, twist, pinch or kink the nylon tube.
• Cover the disconnected fuel tube joint with a plastic bag to prevent damage and contamination.
• If the fuel tube joint and fuel suction plate sub-assembly are stuck, push and pull to release them.

8. REMOVE NO. 1 FUEL TUBE CLAMP

9. REMOVE FUEL PUMP GAUGE RETAINER

(1) Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.

SST: 09808-01071

SST: 09808-14031

09808-01030

09808-01090

HINT:

Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.

(2) While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).

(3) Install SST (handle) to SST (plate).

SST: 09808-01071

SST: 09808-14031

09808-01010

09808-01030

09808-01090

(4) Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing down on SST, rotate SST (handle) slowly to loosen the fuel pump gauge retainer.

NOTICE:

• Do not use any tools other than specified as this may result in damage to the fuel pump gauge retainer or fuel tank assembly.
• Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
• Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.
• Do not spin SST too fast or use an impact wrench as this may result in damage to components.
• If SST comes off of the fuel pump gauge retainer, loosen SST (bolt) and reinstall SST.

(5) While pressing down on the fuel suction tube with pump and gauge assembly, remove the fuel pump gauge retainer.

10. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

(1) Remove the fuel suction tube with pump and gauge assembly from the fuel tank assembly.

NOTICE:

Be careful not to bend the arm of the fuel sender gauge assembly.

(2) Remove the fuel suction tube set gasket from the fuel tank assembly.

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