Fuel tank door hinge

for passenger side:
1. unclip screw cover 'center flap' of inside door opener plastic cover, flap is 3/8"x 3/8" (center of plastic cover)
2. remove phillips screw now showing
3. push fabric panel (edge of door opener plastic cover-at hinged end of chrome handle) to allow uncliping of edge of plastic cover (top rt & lwr rt (for passenger side) of plastic cover)
4. open chrome inside door handle to allow plastic cover to be removed-slide plastic cover toward rear, free end of door to remove cover
5. remove switch panel-gently pry with wide non maring pry bar (cover wide blade screwdriver using cloth) do rear of sw panel 1st (don't pry front edge)
6. slide switch panel toward rear to allow removal
7. remove large phillips screw under sw panel
8. remove the 2 plastic covers near top, hinge edge -use plastic spoon handles to encourage caps to pop off. May also require small screwdriver approx 1/8" in to complete pop off
9. remove the 2 phillips screws w/ captive washers
10. remove 3 phillips/hex screws along the bottom inside of door panel
11. on outside/rear edge of panel push the 2 center pins of each in about 1/8"-this allows the clip to be pulled out w/ pin pushed in
12. remove plastic cover (REAR OF SIDE MIRROR)-pull window edge up and back.
13. lift rear of door panel (not hinge edge) up allow hinge edge to pivot around lower pin in door (hinge edge)
14. remove the 2 rt edge "L" brackets (gently pry center plastic pin out) (note the color and replace as removed)
15. slowly peel the clear plastc away from the non hinged end to expose the plastic panel with 3 phillips head screws
16. remove the 3 screws and panel for access to door handle.
17. using access area now available unlatch the rod attached to exterior door handle (unclip plastic to rotate clip up to allow rod to slide out-toward hinged edge)
18. using access area now available remove rod from ext door handle from inside door area
19. remove the 3 -10mm head bolts
20. remove the ext door handle (bottom edge out first)
reverse order to replace door handle

1. Make sure the fuel tank is 5/8 capacity or less before replacing or a fuel spill could result.
2. Disconnect negative battery cable.
3. Remove the rear lower seat cushion.
4. Push seat back and up to remove seat cushion.
5. Fold back the foam pad covering access cover for modules.
6. Remove plastic access covers from floor pan right side.
7. Disconnect the fuel supply line from module.
8. Mark the module orientation.
9. Drain fuel from right side of fuel tank. Lift module up enough to push hose into tank and drain. Do not spill fuel in interior of vehicle.
10. Pull module up and out of fuel tank.
11. Fuel Pressure regulator location.
12. Note location of ground wire tab location.
13. Remove ground wire.
14. Use a screwdriver and pry up on retaining clip.
15. Clip in the off position.
16. Fuel pressure regulator removed.
17. Remove O-ring from module.

• Reverse to install making sure to use all new O rings and clips and check for leaks post repair.

• If you have any comments please feel free to leave them here.
• Hope this helps and thank you for using FixYa.

Regards, Tony

1. Release the fuel system pressure using the recommended procedure.
2. Remove the fuel pump unit through the access panel in the floor of the trunk. Drain the fuel tank into a portable fuel siphoning container through the opening in the fuel tank where the fuel pump is mounted.

Prior to disconnecting fuel lines, wrap a shop rag around the connections to absorb any fuel spillage due to residual pressure in the lines.

1. Disconnect negative battery cable.
2. Raise and safely support the vehicle. Remove both rear tires.
3. Remove the exhaust pipe rubber insulators off the mounting studs of the rear of the vehicle and in front of the fuel tank.
4. Using grease pencil or paint marker, place alignment marks on the fuel filler hose, filler tube, vent hose and vent tube.
5. Remove the rear splash shield from the right rear wheel well.
6. Disconnect the fuel filler hose and the vent hose near the fuel filter.

1. Disconnect both ends of the sway bar from the stabilizer links. Use a grease pencil or paint marker to outline the position of the crossmember ends on the frame rail.

1. Remove the crossmember mounting bolts and pull the crossmember down until it stops.

1. Place a transmission jack under the fuel tank to support its weight.

The sway bar bracket bolts must be replaced after loosening or removal. Only use original equipment bolts as replacement.

1. Remove the sway bar mounting bracket, heat shield and fuel tank strap. To prevent the sway bar from falling down, install sway bar mounting bracket with the bolts finger-tight only.

1. Carefully and slowly lower the front of the fuel tank. Slide the tank away from the crossmember while pushing the filler vent and fill tube over the crossmember. Detach any remaining fuel or electrical connections. Lower the fuel tank.

To install:

1. Position the tank on the transmission jack or other suitable lift, with the shield and the tank strap in place. Raise the tank over the crossmember and place it in the proper position. Be sure that the electrical connector, pressure relief/rollover valve hose, fuel supply and return lines are accessible through the opening in the trunk. Check to be sure that nothing is pinched or kinked in any way.
2. Push the vent and the filler tube over the crossmember. Rotate the sway bar into position and install the sway bar brackets.
3. Raise the tank into place and position the sway bar mounting bracket and the tank straps in place. Tighten the bolts to 44 ft. lbs. (60 Nm).
4. Raise the crossmember into position and align with the locating marks made during removal. Install bolts and tighten to 70 ft. lbs. (95 Nm).
5. Reconnect the filler tube and vent tube making sure to align with the marks made during removal.
6. Connect the sway bar ends to the link arms and tighten sway bar mounting nuts to 74 ft. lbs. (100 Nm).
7. Install the exhaust onto the hangers. Install the rear splash shield in the right rear wheel well.
8. Install the rear wheels and lug nuts. Tighten the lug nuts, in a star pattern sequence, to 95-100 ft. lbs. (129-135 Nm).
9. Lower the vehicle.
10. Install the fuel pump module.
11. Connect the fuel supply, return and vent tubes. After installation of the quick-connect fittings, check for proper connection by pulling back on the quick-connect fitting. The tube should lock in place. If the connection is not complete, make sure the black plastic ring is not causing the locking retainer to jam in the release position.
12. Install the fuel pump access cover and gasket. Tighten the fasteners and install the trunk liner.
13. Install the filler cap and reconnect the negative battery cable.
14. With the ignition in the ON position, access the DRB III ASD Fuel System Test to pressurize the fuel system. Check for leaks.

1. Check the rear wheel alignment and adjust, if necessary.

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REMOVAL & INSTALLATION

The rear suspension on LH platform vehicles is a fully independent suspension. A stabilizer bar (also called a sway bar) is mounted in rubber isolator bushings and connects the rear struts through links. Note that the fuel tank must be removed to remove the stabilizer bar.

CAUTION OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1. Disconnect the negative battery cable. Relieve the fuel system pressure.
2. Raise and safely support the vehicle.
3. Remove both rear wheels.

1. Position a transmission jack under the fuel tank just forward of the crossmember to help support the fuel tank when crossmember is removed.
2. Remove the four crossmember to frame rail attaching bolts. Remove the fuel tank.
3. Remove the stabilizer bar to link assembly attaching nuts and remove the bar and isolator bushings as an assembly from the vehicle. Inspect the isolator bushings for damage or excessive wear and replace, if necessary.

To install:

1. Inspect for broken or distorted retainers and bushings. If bushing replacement is required, replacement bushings can be installed by locating the split in the bushing, prying open and removing the defective bushing from around the stabilizer bar.
2. Install the stabilizer bar and isolator bushings back into the vehicle as an assembly making sure bar is centered in vehicle so it doesn't contact other suspension components.
3. Install stabilizer bar attaching link onto stabilizer bar. Install new link to bar attaching nuts and tighten to 70 ft. lbs. (95 Nm).

Replace the sway bar bracket bolt with new after loosening or removing them. Only use original equipment bolts as replacements.

1. Install the fuel tank back onto the vehicle.
2. Position the crossmember on frame rails and install four mounting bolts. Tighten attaching bolts to 70 ft. lbs. (95 Nm).
3. Remove transmission jack from under the fuel tank.
4. Install the rear wheels and lug nuts. Tighten the lug nuts, in a star pattern sequence, to 95-100 ft. lbs. (129-135 Nm).
5. Lower the vehicle. Reconnect the negative battery cable.
6. Pressurize the fuel system and check for leaks.
7. Check and reset the rear wheel toe to specifications as required.

The fuel filter located on top of fuel tank beside the fuel pump. Accessible by removing the rear seat and detaching the inspection panel of the fuel pump.

Hope this can help.

The Fuel Pump is Located In the Fuel TANK and is ONLY Accessable With TANK REMOVED

Fuel pump is located inside the fuel tank access cover location. Here's the details:

1. Properly relieve the fuel system pressure.
2. Disconnect the negative battery cable.
3. Open the rear access door.
4. Release the catch for the back seat and tilt the seat out of the way.
5. Move the carpet behind the seat that covers the fuel pump access panel.
6. Disconnect the fuel pump electrical connectors.
7. Remove the screw securing the ground wire.
8. Remove the four screws securing the fuel pump access panel and position it out of the way.
9. Remove the hose clamps connecting the fuel hoses to the fuel pump.
10. Disconnect the fuel hoses from the fuel pump.
11. Disconnect the fuel tank pressure sensor electrical connector.
12. Remove the eight retaining screws securing the sender assembly to the tank.
    WARNING The fuel assembly is easily damaged. Use care when removing the assembly from the tank.
    
13. While twisting and tilting, gradually lift the fuel sender assembly and remove from the tank.
14. Wrap the fuel pump assembly in a rag before removing the assembly from the vehicle.
15. Cover or seal the fuel tank until installing the fuel pump assembly.
16. Remove the retaining hardware that holds the sender to the fuel pump assembly.

To install:

1. Install the retaining hardware that holds the sender to the fuel pump assembly.
2. Remove the temporary covering or seal that was used to protect the tank.
3. Install the fuel pump into the access port on top of the fuel tank.
4. Carefully, twist the fuel pump as necessary to properly position it in the fuel tank.
5. Install the eight retaining screws securing the sender assembly to the tank.
6. Connect the two fuel hoses to the pump and secure with clamps.
7. Connect the fuel tank pressure sensor electrical connector.
8. Insert the ground wire and fuel pump electrical connector through the access hole and install the access cover.
9. Connect the fuel pump electrical connector.
10. Secure any loose wiring with adhesive tape and reattach the carpeting.
11. Release the catch for the rear seat and put the rear seat in the normal position.
12. Close the rear access door.
13. Reconnect the negative battery cable.

I can help you further and show you where you can access the information for free. Good luck!

Removal

1. Relieve the Fuel System Pressure . Refer to the procedure in this section.
   

Cushion Cover and Pad, Rear Seat — One-Piece and 50/50 Split Fold Removal

1. Remove the two rear seat cushion bolts.
   

1. Fold the rear seat back cover and cushion (60084) forward.
   

1. Carefully pull the rear seat cushion and cover (60030) out from under the rear seat back cover and cushion and remove the rear seat cushion and cover from the vehicle
   

1. Remove the rear seat cushion and cover (60030). Refer to Section 01-10 for the removal procedure.
   

1. Remove the three luggage compartment floor cover hold-down pins and fold the luggage compartment floor cover (45455) forward until the fuel pump assembly access plate is visible.
   

1. Remove the four fuel pump assembly access plate screws, the ground lead, and the fuel pump assembly access plate from the chassis.
   
   
   
   
   

1. Disconnect the fuel pump assembly electrical connector.
   
   
   
   
   

1. On 4-door vehicles, remove the fuel vapor tube shutoff valve bolt and the evaporative emission tube shut off valve (9G332) from the bracket on the fuel pump assembly housing.
   
   
   
   
   

1. Loosen the two hose clamps and disconnect the two fuel pump hoses from the fuel pump hose fittings on the fuel pump assembly housing.
   
   
   
   
   

1. Remove the four screws (2-door) or eight screws (4-door) and lift the fuel pump assembly housing from the fuel tank (9002).
   
   
   
   
   

1. Disconnect the fuel level sensor electrical connector.
   

1. Remove the two fuel level sensor washers and fuel level sensor nuts and the fuel level sensor.
   
   

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Section 10-01: Fuel Tank, Filters, Lines and Electric Fuel Pump 1996 Aspire Workshop Manual
REMOVAL AND INSTALLATION Fuel Pump Removal

1. Remove the fuel level sensor. Refer to the Fuel Level Sensor removal procedure in this section.
   

1. Remove the fuel pump screw, fuel pump grommet and the fuel pump bracket from the bottom of the fuel pump (9350).
   
   
   
   
   

1. Remove the fuel tank sender filter bracket, fuel tank sender filter (9A011) and the fuel tank sender filter retainer from the fuel pump.
   

1. Disconnect the fuel pump electrical connector.
   

1. Remove the clamp and the fuel pump from the fuel pump assembly housing.
   

If you're on the smallish side and pretty limber, you might avoid removing the rear wheel. If not, you will likely need to remove the rear wheel and put the van on jack stands securely. I would remove the underside splash shield and gain access from underneath. It looks like you will need to unscrew the plastic insert that surrounds the filler neck inside the area that is exposed when you open the fuel door. Make sure you get the vent hooked up correctly when you are done.

Go to your nearest Toyota dealer. Purchase this part number: 77360-22020; approx 4 dollars.

Open the fuel door. Being careful, remove the leftover plastic that is hooked by the door hinge. Insert the new spring assembly under the slot, and press it in until it clicks into place. Very easy to do.
Hope this helps, and thanks for choosing FixYa.