Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCEFUEL DELIVERYENGINE FUEL SYSTEMFUEL TANK ASSY (FF)COMPONENTSREMOVAL & INSTALLATION

2004 Toyota Matrix XR, FWD, Standard

Removal & Installation

2004 Toyota Matrix XR, FWD, StandardSECTION Removal & Installation

REMOVE SEPARATE TYPE REAR SEAT CUSHION ASSY (See REMOVAL & INSTALLATION )
REMOVE REAR FLOOR SERVICE HOLE COVER (See REMOVAL & INSTALLATION )
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.
DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY (See REMOVAL & INSTALLATION )
DISCONNECT FUEL EMISSION TUBE SUB-ASSY No. 1 (See REMOVAL & INSTALLATION )
REMOVE FUEL TANK VENT TUBE SET PLATE (See REMOVAL & INSTALLATION )
REMOVE FUEL PUMP ASSEMBLY (See REMOVAL & INSTALLATION )
REMOVE FUEL SUCTION TUBE SET GASKET (See REMOVAL & INSTALLATION )
DRAIN FUEL
REMOVE CONSOLE BOX ASSY REAR (2ZZ-GE ENGINE TYPE)

Fig 1: Removing Console Box
Courtesy 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.
REMOVE FLOOR PANEL BRACE FRONT

Fig 2: Removing Floor Panel Brace Front
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 nuts and floor panel brace front.
REMOVE EXHAUST PIPE ASSY FRONT
1. Using a clip remover, remove the clip.
  
  Fig 3: Removing Clip Using Clip Remover
  Courtesy 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
    Courtesy 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.
REMOVE FUEL TANK PROTECTOR No. 1

Fig 5: Removing Fuel Tank Protector No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 5 bolts and fuel tank protector.
SEPARATE PARKING BRAKE CABLE ASSY No. 2

Fig 6: Separating Parking Brake Cable Assy No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 installing bolts of the parking brake cable.
SEPARATE PARKING BRAKE CABLE ASSY No. 3

Fig 7: Separating Parking Brake Cable Assy No. 3
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 installing bolts of the parking brake cable.
DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY

Fig 8: Disconnecting Fuel Tank Main Tube Sub-Assy
Courtesy 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.