Toyota Yaris: Fuel Tank / Removal

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (fuel) / Fuel Tank / Removal

REMOVAL

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 tank assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

Gas leaks from exhaust system is repaired

Inspection after repair

  • Poor idle, etc.
  • Engine start function, etc.

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.
  • The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank assembly may fall off the engine lifter.

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

    Lane tracing assist system

    Drive the vehicle straight ahead at 35 km/h (22 mph) or more for 5 second or more.

    Pre-collision system

    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.

    Air conditioning system

    After the ignition switch is turned to ON, the servo motor standard position is recognized.

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PROCEDURE

1. DRAIN FUEL

2. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

Click here

3. REMOVE REAR FLOOR SERVICE HOLE COVER (for RH Side)

Click here

4. REMOVE NO. 1 FUEL TUBE CLAMP

Click here

5. REMOVE FUEL PUMP GAUGE RETAINER

Click here

6. REMOVE FUEL TANK VENT TUBE ASSEMBLY

Click here

7. REMOVE DIFFERENTIAL CARRIER ASSEMBLY

Click here

8. REMOVE NO. 2 FUEL TANK PROTECTOR

(a) Remove the nut, 4 clips and No. 2 fuel tank protector.

9. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

(a) Remove the 4 clips and No. 1 fuel tank protector sub-assembly.

10. REMOVE NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY

(a) Remove the No. 1 fuel evaporation tube sub-assembly from the fuel pipe.

Click here

11. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Remove the fuel tank main tube sub-assembly from the fuel pipe.

Click here

12. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

(a) Loosen the hose clamp to disconnect the fuel tank to filler pipe hose from the fuel tank assembly.

13. DISCONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY

(a) Disconnect the fuel tank filler pipe sub-assembly.

14. DISCONNECT NO. 6 FUEL TANK BREATHER TUBE

(a) Disconnect the No. 6 fuel tank breather tube.

15. REMOVE FUEL TANK ASSEMBLY

CAUTION:

The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank assembly may fall off the engine lifter.

(a) Support the fuel tank assembly using an engine lifter.

HINT:

Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal.

(b) Remove the 4 bolts and 2 fuel tank band sub-assemblies.

(c) Lower the engine lifter to remove the fuel tank assembly.

NOTICE:

  • Be careful not to drop the fuel tank assembly.
  • When removing the fuel tank assembly, tilt it slightly to prevent it from interfering with the surrounding parts.

16. REMOVE CHARCOAL CANISTER OUTLET HOSE

(a) Disengage the clamp to remove the charcoal canister outlet hose from the fuel tank assembly.

    Components

    COMPONENTS ILLUSTRATION *1 CHARCOAL CANISTER OUTLET HOSE *2 FUEL TANK ASSEMBLY *3 NO. 6 FUEL TANK BREATHER TUBE *4 FUEL TANK FILLER PIPE SUB-ASSEMBLY *5 FUEL TANK TO FILLER PIPE HOSE *6 FUEL TANK MAIN TUBE SUB-ASSEMBLY *7 NO...

    Installation

    INSTALLATION PROCEDURE 1. INSTALL CHARCOAL CANISTER OUTLET HOSE (a) Engage the clamp to install the charcoal canister outlet hose to the fuel tank assembly...

    Other information:

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    Categories

    Fuel-Filler Lid and Cap

    WARNING

    When removing the fuel-filler cap, loosen the cap slightly and wait for any hissing to stop, then remove it

    Fuel spray is dangerous. Fuel can burn skin and eyes and cause illness if ingested. Fuel spray is released when there is pressure in the fuel tank and the fuel-filler cap is removed too quickly.

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