I need to replace my fuel sender unit in my Corolla and cant seem to get the big green screw nut off as in the picture attached. Just wondered if anyone here has any ideas or if they have managed to remove something similar.

 

As you will see I have been trying to hammer it round with a blunt chisel but have damaged on of the lugs  so stopped.

 

I have never come across this type of fitting before as they usually have torx screws holding them in place and not a large green screw 

 

Thanks everyone.

You could improvise a tool for it, as shown in Google images:

 

https://www.google.co.uk/search?q=fuel+pump+removal+tool&client=firefox-a&hs=Ewe&rls=org.mozilla:en-US:official&tbm=isch&tbo=u&source=univ&sa=X&ei=GrD6UcO5JJSQ0QXIkIDICA&ved=0CD8QsAQ&biw=1440&bih=768

 

Or you could try tapping it around (it looks as though you've already tried this) after pouring some boiling water over it.

Thanks, I will try and work something out, Toyota must have some special tool to remove this, Nightmare. I disconnected the plug and took the petrol gauge wire to ground and the petrol gauge shot to full so I know its not the gauge but its being so close to solving the cars problem and then becoming stuck due to one big plastic nut lol.

Big set of grips

Or alternatively eat some spinach

Big set of grips

 

Didn't think you could get them that big, Thought an oil filter removal chain would do but the dam things just to short.

Get some small angle brackets and screw them to a block of wood.

G clamp?

Try an old Timing Belt or Auxillary belt and a pair of Vice Grips. I use same method for removing oil filters if i dont have an oil filter wrench handy.

Like this...

 

Soon as I saw this I was thinking old timing belt and mole grips like above.... ade is right on the money with that suggestion above. Top banana.

Soon as I saw this I was thinking old timing belt and mole grips like above.... ade is right on the money with that suggestion above. Top banana.

better than the answer I had in mind; I was gonna say gas-axe the ****er off

If it's a sacrificial component, split it like you would a steel one (but using less force obviously).

Oil filter wrench/tool?

 

Strap wrench

 

https://www.google.co.uk/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&cad=rja&ved=0CDQQFjAB&url=http%3A%2F%2Fwww.diy.com%2Fnav%2Ffix%2Fhandtools-storage-workwear%2Fhandtools%2Fplumbing-tools%2Fplumbing_wrenches%2FB-and-Q-150mm-Strap-Wrench-11247648&ei=jij8UbLBGMm9Od2FgJgP&usg=AFQjCNH1qGPoHyxFxJgyJhKtk0LrJ_P7GQ&sig2=HeRn618nsm1ULxEoP-PSiQ&bvm=bv.50165853,d.ZWU

 

 

 

Steve.

Another one for oil filter tool, either the Steele band one or the rubber/nylon one.

I have done fuel pumps on Ford Focus and Freelander, on both occasions I used a short piece of wood with a good 90' square end, held it against the raised bits on the plastic ring and tapped gently with a hammer, then move to another lobe and tap again until it starts to move, when pump is changed reverse the tapping to tighten!!

 

 So be gentle and give it a little tap, tap tappy........

Well got it off only to find that the fuel sender is ok, I noticed the float was worn on one edge so looked in the tank and there is a tray of some kind that isnt fixed and it is moving freely in my tank and has been obstructing the float stopping it from reading correctly. I filmed this today, here is the link...

 

http://www.youtube.com/watch?v=J9FVBbAxKDE

 

I am unsure what purpose this tray is doing and I cant get it out as its square and wont fit through the hole. Does anyone know what this is I am not sure how it sits originally and if it was perhaps bonded in someway to the bottom of the tank and now this bonding has failed leaving it to move around effecting the float.

 

A new tank will cost £430 from Toyota - Unsure what to do...for now Its just been put back together and left :think:  Thanks.

It looks as though it should fit to something with pegs on it to match the holes in the tray ends.  I suspect that it is there to form and keep a small reservoir of fuel close to the pump inlet so as not to let it run dry on corners when the tank fuel level is low.

It looks as though it should fit to something with pegs on it to match the holes in the tray ends.  I suspect that it is there to form and keep a small reservoir of fuel close to the pump inlet so as not to let it run dry on corners when the tank fuel level is low.

 

Thanks, I felt around in the tank along the top as far as I could and I couldn't find any lugs, recesses or anything to suggest it could be held in place. Just wish I knew how Toyota fit these in. 

Hmm, yeah that looks like whats called a 'Swirl Pot' designed to stop fuel surge when cornering, but it should be fixed in place somehow.

Theres no lugs that come down from the fuel pump assembly that hold it there is there? Inspect it and see if it looks as if any have broken off.

Certainly shouldnt move like that.

Have you considered a 2nd hand Fuel Tank from a Breakers or eBay?

Have you considered a 2nd hand Fuel Tank from a Breakers or eBay?

 

I have phoned all over and my chassis number comes up as an imported car so the tank is unavailable as its not on their database, However when I call Toyota the confirm what I already know is an imported car and quoted the cost for a new tank as £305. I brimmed the tank today and filled it to maximum so that the float is well above this tray that is moving around inside the tank (as in the video above)

 

Its reading correct at this moment in time but I know If I let it drop to below half a tank its going to get stuck in the tray and then I'm back to square one. Just have to keep it topped up - Talk about a pain in the arse lol  

Have you tried Dempseys?

Here is a link to what they are breaking, a few Corolla Imports by the looks of it.

They might even have one on the shelf from a previously broken one.

 

http://www.dempseydismantlers.com/productsShand/toyotashand/toyotashand.html

 

EDIT: Just realised they are not in the UK! Might still be worth a try though.

Also, have you tried using FINDAPART?

Edited 10 August, 201312 yr by Ade VRS

Have you tried Dempseys?

Here is a link to what they are breaking, a few Corolla Imports by the looks of it.

They might even have one on the shelf from a previously broken one.

 

http://www.dempseydismantlers.com/productsShand/toyotashand/toyotashand.html

 

EDIT: Just realised they are not in the UK! Might still be worth a try though.

Also, have you tried using FINDAPART?

 

Thanks I will have a look - The car started life in Ireland and was imported to the UK when it was 10 months old and had a UK reg number put onto it at this time also. Thanks everyone for the help - cheers.

Edited 11 August, 201312 yr by justinbarrow