Installation

2GR-FSE FUEL: FUEL PUMP: INSTALLATION

INSTALLATION

1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY

(a) Apply a light coat of gasoline to 2 new O-rings, and install them to the fuel pressure regulator.

(b) Install the fuel pressure regulator to the fuel relief valve.
(c) Install the clip to the relief valve.
2. INSTALL JET PUMP

(a) Apply a light coat of gasoline to a new O-ring, and install a new O-ring and the jet pump to the fuel relief valve.
3. INSTALL FUEL RELIEF VALVE ASSEMBLY

(a) Apply a light coat of gasoline to a new O-ring, and install a new O-ring and the fuel relief valve to the fuel filter.
4. INSTALL FLANGE ASSEMBLY

(a) Apply a light coat of gasoline to a new O-ring, and install the O-ring to the flange. Then attach the 2 claws to install the flange to the fuel filter.
5. INSTALL FUEL PUMP ASSEMBLY

(a) Install the fuel pump spacer to the fuel pump.
(b) Apply a light coat of gasoline to a new seal, and install it to the fuel pump.
(c) Attach the 2 claws to install the fuel pump to the fuel filter.

(d) Connect the 2 connectors and terminal, and install the fuel pump wire.
6. INSTALL NO. 1 FUEL SUB-TANK

(a) Apply gasoline to a new O-ring and install it to the jet pump.
(b) Install the jet pump while aligning it to the installation position of the sub-tank.

(e) Install a new E-ring.
7. INSTALL FUEL SENDER GAUGE ASSEMBLY

(a) Set the fuel sender gauge to the sub-tank. Then slide the sender gauge downward to install it.
(b) Connect the fuel sender gauge connector.
8. INSTALL FUEL SUCTION WITH PUMP AND GAUGE ASSEMBLY
(a) Apply a light coat of gasoline to a new gasket, and install it to the fuel tank.
(b) Connect the fuel return vent tube and set the fuel suction with pump and gauge assembly.
NOTICE:
- Be careful not to bend the arm of the fuel sender gauge.
- When connecting the fuel return vent, tube connector do not forcibly pull the tube.

(d) While holding the flange assembly by hand, align the starting marks of a new fuel pump gauge retainer and the fuel tank. Then install the fuel pump gauge retainer to the fuel tank.

(e) Using a 6 mm socket, set SST to the fuel pump gauge retainer.
SST: 09808-14020
09808-01410
09808-01420
09808-01430
HINT: Fit the tips of SST on the ribs of the retainer.
NOTE:
Use SST. Do not use any other tools such as a screwdriver.

(f) Hold SST with one hand and use SST to tighten the fuel pump gauge retainer 2 turns so that the starting mark on the retainer is within the indicated range in the illustration.

(g) Connect the fuel pump tube.
(1) Push the fuel tube joint into the plug of the fuel suction plate, then install the tube joint clip.
NOTICE:
- Check that there are no scratches or foreign matter around the connected part of the fuel tube joint and plug before performing this work.
- Check that the fuel tube joint is securely inserted.
- Check that the tube joint clip is on the collar of the fuel tube joint.
- After installing the tube joint clip, check that the fuel tube cannot be pulled out.

9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. INSPECT FOR FUEL LEAK Testing and Inspection

11. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER
(a) Connect the fuel pump connector.
(b) Install the service hole cover with new butyl tape.

12. INSTALL ROOM NO. 3 PARTITION PAD
(a) Install the partition pad with the clip.
13. INSTALL REAR SEAT CUSHION ASSEMBLY Installation
14. PERFORM INITIALIZATION
(a) Perform initialization Repair Instruction - Initialization.
NOTE:
Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.