Page 1145 of 3000
FU–302GR-FE FUEL – FUEL PUMP
FU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
(See page FU-1)
2. REMOVE CHARCOAL CANISTER PROTECTOR
(a) Remove the 6bolts and the charcoal canister
protector.
3. REMOVE REAR FLOOR NO. 2 CROSSMEMBER
BRACE LH (See page FU-41)
4. REMOVE FUEL TANK FILLER HOSE COVER (See
page FU-41)
5. REMOVE FUEL TANK ASSEMBLY (See page FU-41)
Page 1146 of 3000

2GR-FE FUEL – FUEL PUMPFU–31
FU
DISASSEMBLY
1. REMOVE FUEL TANK TO FILLER PIPE HOSE (See
page FU-43)
2. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Remove the tube joint clip, and pull out the fuel main
tube.
NOTICE:
• Check if there is any dirt or mud around the
connector before this operation and remove
the dirt as necessary
• Be careful of mud because the quick
connector has an O-ring which seals the pipe
and connector that can be contaminated.
• Do not use any tool in this operation.
• Do not bend or twist the nylon tube. Protect
the connector by covering it with a vinyl or
plastic bag.
• When the pipe and connector are stuck, push
and pull the connector to release and pull the
connector out carefully.
(b) Unfasten the 4 claws and remove the fuel tank main
tube from the fuel tank.
3. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH
PUMP AND GAUGE
(a) Using SST, loosen the fuel pump gauge retainer.
SST 09808-14020 (09808-01410, 09808-01420,
09808-01430)
HINT:
A rib on the fuel pump gauge retainer can be fitted
into a tip of SST.
(b) Remove the fuel pump gauge retainer.
(c) Remove the fuel suction tube assembly with pump
and gauge and the fuel suction tube set gasket from
the fuel tank.
NOTICE:
Be careful not bend the arm of the fuel sender
gauge.
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FU–322GR-FE FUEL – FUEL PUMP
FU
4. REMOVE FUEL SENDER GAUGE ASSEMBLY
(a) Disconnect the fuel sender gauge connector.
(b) Unlock the fuel sender gauge and slide it to remove.
5. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY
(a) Using a screwdriver with the tip wrapped in tape,
disconnect the 4 snap-claws from the claw holes
and remove the fuel suction plate.
NOTICE:
Do not damage the fuel suction plate and the
No. 1 fuel suction support.
6. REMOVE FUEL PUMP
(a) Disconnect the fuel pump connector.
(b) Using a small screwdriver with the tip wrapped in
tape, disconnect the 2 claws from the claw holes
and pull out the fuel pump.
NOTICE:
Do not damage the fuel pump and the fuel
suction plate.
(c) Remove the O-ring and the fuel pump spacer from
the fuel pump.
7. REMOVE FUEL FILTER ASSEMBLY
(a) Using a small screwdriver, pry out the clip.
(b) Remove the fuel filter assembly from the fuel pump.
8. REMOVE NO. 1 FUEL TUBE JOINT
(a) Remove the connector.
(b) Using a screwdriver with the tip wrapped in tape,
disconnect the snap-claw from the claw hole and
pull out the No. 1 fuel tube joint.
NOTICE:
Do not damage the No. 1 fuel tube joint and the
fuel suction plate.
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Page 1148 of 3000
FU–302GR-FE FUEL – FUEL PUMP
FU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
(See page FU-1)
2. REMOVE CHARCOAL CANISTER PROTECTOR
(a) Remove the 6bolts and the charcoal canister
protector.
3. REMOVE REAR FLOOR NO. 2 CROSSMEMBER
BRACE LH (See page FU-41)
4. REMOVE FUEL TANK FILLER HOSE COVER (See
page FU-41)
5. REMOVE FUEL TANK ASSEMBLY (See page FU-41)
Page 1149 of 3000

2GR-FE FUEL – FUEL PUMPFU–31
FU
DISASSEMBLY
1. REMOVE FUEL TANK TO FILLER PIPE HOSE (See
page FU-43)
2. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Remove the tube joint clip, and pull out the fuel main
tube.
NOTICE:
• Check if there is any dirt or mud around the
connector before this operation and remove
the dirt as necessary
• Be careful of mud because the quick
connector has an O-ring which seals the pipe
and connector that can be contaminated.
• Do not use any tool in this operation.
• Do not bend or twist the nylon tube. Protect
the connector by covering it with a vinyl or
plastic bag.
• When the pipe and connector are stuck, push
and pull the connector to release and pull the
connector out carefully.
(b) Unfasten the 4 claws and remove the fuel tank main
tube from the fuel tank.
3. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH
PUMP AND GAUGE
(a) Using SST, loosen the fuel pump gauge retainer.
SST 09808-14020 (09808-01410, 09808-01420,
09808-01430)
HINT:
A rib on the fuel pump gauge retainer can be fitted
into a tip of SST.
(b) Remove the fuel pump gauge retainer.
(c) Remove the fuel suction tube assembly with pump
and gauge and the fuel suction tube set gasket from
the fuel tank.
NOTICE:
Be careful not bend the arm of the fuel sender
gauge.
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FU–322GR-FE FUEL – FUEL PUMP
FU
4. REMOVE FUEL SENDER GAUGE ASSEMBLY
(a) Disconnect the fuel sender gauge connector.
(b) Unlock the fuel sender gauge and slide it to remove.
5. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY
(a) Using a screwdriver with the tip wrapped in tape,
disconnect the 4 snap-claws from the claw holes
and remove the fuel suction plate.
NOTICE:
Do not damage the fuel suction plate and the
No. 1 fuel suction support.
6. REMOVE FUEL PUMP
(a) Disconnect the fuel pump connector.
(b) Using a small screwdriver with the tip wrapped in
tape, disconnect the 2 claws from the claw holes
and pull out the fuel pump.
NOTICE:
Do not damage the fuel pump and the fuel
suction plate.
(c) Remove the O-ring and the fuel pump spacer from
the fuel pump.
7. REMOVE FUEL FILTER ASSEMBLY
(a) Using a small screwdriver, pry out the clip.
(b) Remove the fuel filter assembly from the fuel pump.
8. REMOVE NO. 1 FUEL TUBE JOINT
(a) Remove the connector.
(b) Using a screwdriver with the tip wrapped in tape,
disconnect the snap-claw from the claw hole and
pull out the No. 1 fuel tube joint.
NOTICE:
Do not damage the No. 1 fuel tube joint and the
fuel suction plate.
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2GR-FE FUEL – FUEL PUMPFU–33
FU
9. REMOVE FUEL PUMP HARNESS
(a) Remove the fuel pump harness from the No. 1 fuel
tube joint.
10. REMOVE FUEL PRESSURE REGULATOR
ASSEMBLY
(a) Remove the clip.
(b) Pull out the fuel pressure regulator from the fuel
suction plate.
(c) Remove the 2 O-rings from the fuel pressure
regulator.
INSPECTION
1. INSPECT FUEL PUMP
(a) Inspect fuel pump resistance.
(1) Using an ohmmeter, measure the resistance
between the terminals.
Standard resistance
(b) Inspect fuel pump operation
(1) Apply battery voltage to both the terminals.
Check that the pump operates.
NOTICE:
• These tests must be done quickly (within
10 seconds) to prevent damage to the
pump.
• Keep fuel pump as far away from the
battery as possible.
• Always do the switching at the battery
side.
REASSEMBLY
1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
(a) Apply a light coat of gasoline or spindle oil to the 2
new O-rings, and install it to the fuel pressure
regulator.
(b) Apply a light coat of gasoline or spindle oil to the 2
O-rings again, and install the fuel pressure regulator
to the No. 1 fuel tube joint.
(c) Install the clip.
2. INSTALL FUEL PUMP HARNESS
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Tester Connection Condition Specified Condition
1 - 2 always0.2 to 3.0
at 20
C (68F)
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FU–342GR-FE FUEL – FUEL PUMP
FU
3. INSTALL NO. 1 FUEL TUBE JOINT
(a) Apply a light coat of gasoline or spindle oil to a new
O- ring, and install it to the No. 1 fuel tube joint.
(b) Apply a light coat of gasoline or spindle oil to the O-
ring again, and install the No. 1 fuel tube joint to the
fuel suction plate.
(c) Connect the connector.
4. INSTALL FUEL FILTER ASSEMBLY
(a) Install the fuel filter with a new clip.
5. INSTALL FUEL PUMP
(a) Install the fuel pump spacer to the fuel pump.
(b) Apply a light coat of gasoline or spindle oil to a new
O- ring, and install it to the fuel pump.
(c) Apply a light coat of gasoline or spindle oil to the O-
ring again, and install the fuel pump to the fuel
suction plate.
(d) Connect the fuel pump connector.
6. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY
(a) Apply a light coat of gasoline or spindle oil to a new
O- ring, and install it to the No. 1 fuel tube joint.
(b) Apply a light coat of gasoline or spindle oil to the O-
ring again, and install the fuel suction plate to the
No. 1 fuel suction support.
7. INSTALL FUEL SENDER GAUGE ASSEMBLY
8. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH
PUMP AND GAUGE
NOTICE:
Prior to assembly, all the new components must be
stabilized at room temperature for minimum 12
hours.
(a) Ensure fuel suction tube set gasket groove is clean
and free of foreign particles.
(b) Install a new fuel suction tube set gasket to the fuel
tank.
(c) Make sure that the fuel suction tube set gasket sits
in the groove.
(d) Align the arrow mark of the fuel suction tube
assembly with pump and gauge and the tank
suction tube support.
NOTICE:
Be careful not bend the arm of the fuel sender
gauge.
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