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2GR-FE FUEL – FUEL PUMPFU–35
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(e) Align marks on a new fuel pump gauge retainer and
the fuel tank.
(f) Position the fuel pump gauge retainer on top of the
fuel suction tube assembly with pump and gage
flange while pushing down the flange on center.
(g) While holding the fuel suction tube assembly with
pump and gauge, tighten the fuel pump gauge
retainer one complete turn by hand.
NOTICE:
• Make sure the fuel suction tube with pump
and gauge anti-rotation tab is in the groove
during above operation.
• "S" arrow on the fuel tank indicates 0 degrees
position.
(h) Ensure that no cross threading occurred during
installation by checking the gap between the fuel
pump gauge retainer and the fuel tank. Confirm that
the gap is even. If cross threading occurred, remove
the fuel pump gauge retainer and repeat step (g).
(i) Using SST, tighten the fuel pump gauge retainer to
the specified torque.
SST 09808-14020 (09808-01410, 09808-01420,
09808-01430)
Torque: 70 to 90 N*m (714 to 918 kgf*cm, 52 to
67 ft.*lbf)
NOTICE:
• No ratcheting effect allowed when tightening
the fuel pump gauge retainer.
• No grease or lubrication allowed on parts
during installation.
HINT:
A rib on the fuel pump gauge retainer can be fitted
into a tip of the SST.
(j) Install the fuel pump gauge retainer by one and half
turn so that the triangle mark on the fuel pump
gauge retainer is between 475
and 535 from the
start position.
(k) If the triangle mark is not reached 475
, confirm that
no cross threading occurred by measuring the gap
between the fuel pump gauge retainer and the fuel
tank.
If cross threading occurred, replace the fuel pump
gauge retainer, the gasket and the tank suction tube
support.
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FU–362GR-FE FUEL – FUEL PUMP
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(l) Replace the tank suction tube support.
(1) Remove the tank suction tube support from the
fuel tank.
(2) Install the tank suction tube support to the fuel
tank as shown in the illustration.
(m) Put a mark on the fuel pump gauge retainer and the
fuel tank with paint. This will be the evidence that
the fuel pump gauge retainer has been removed.
9. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Install in the fuel return tube with the tube joint clip.
NOTICE:
• Check that there is no scratch or foreign
objects on the connecting part.
• Check that the fuel tube joint is inserted
securely.
• 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 joint has not been pulled off.
10. INSTALL FUEL TANK TO FILLER PIPE HOSE (See
page FU-44)
A079527E01
A165504
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A165008E01
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2GR-FE FUEL – FUEL PUMPFU–37
FU
INSTALLATION
1. INSTALL FUEL TANK ASSEMBLY (See page FU-44)
2. INSPECT FOR FUEL LEAK (See page FU-7)
3. INSTALL FUEL TANK FILLER HOSE COVER (See
page FU-45)
4. INSTALL REAR FLOOR NO. 2 CROSSMEMBER
BRACE LH (See page FU-46)
5. INSTALL CHARCOAL CANISTER PROTECTOR
(a) Install the 6bots and the charcoal canister protector.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
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2GR-FE FUEL – FUEL PUMPFU–33
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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
A079773E01
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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
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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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2GR-FE FUEL – FUEL PUMPFU–35
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(e) Align marks on a new fuel pump gauge retainer and
the fuel tank.
(f) Position the fuel pump gauge retainer on top of the
fuel suction tube assembly with pump and gage
flange while pushing down the flange on center.
(g) While holding the fuel suction tube assembly with
pump and gauge, tighten the fuel pump gauge
retainer one complete turn by hand.
NOTICE:
• Make sure the fuel suction tube with pump
and gauge anti-rotation tab is in the groove
during above operation.
• "S" arrow on the fuel tank indicates 0 degrees
position.
(h) Ensure that no cross threading occurred during
installation by checking the gap between the fuel
pump gauge retainer and the fuel tank. Confirm that
the gap is even. If cross threading occurred, remove
the fuel pump gauge retainer and repeat step (g).
(i) Using SST, tighten the fuel pump gauge retainer to
the specified torque.
SST 09808-14020 (09808-01410, 09808-01420,
09808-01430)
Torque: 70 to 90 N*m (714 to 918 kgf*cm, 52 to
67 ft.*lbf)
NOTICE:
• No ratcheting effect allowed when tightening
the fuel pump gauge retainer.
• No grease or lubrication allowed on parts
during installation.
HINT:
A rib on the fuel pump gauge retainer can be fitted
into a tip of the SST.
(j) Install the fuel pump gauge retainer by one and half
turn so that the triangle mark on the fuel pump
gauge retainer is between 475
and 535 from the
start position.
(k) If the triangle mark is not reached 475
, confirm that
no cross threading occurred by measuring the gap
between the fuel pump gauge retainer and the fuel
tank.
If cross threading occurred, replace the fuel pump
gauge retainer, the gasket and the tank suction tube
support.
A165002E01
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FU
(l) Replace the tank suction tube support.
(1) Remove the tank suction tube support from the
fuel tank.
(2) Install the tank suction tube support to the fuel
tank as shown in the illustration.
(m) Put a mark on the fuel pump gauge retainer and the
fuel tank with paint. This will be the evidence that
the fuel pump gauge retainer has been removed.
9. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Install in the fuel return tube with the tube joint clip.
NOTICE:
• Check that there is no scratch or foreign
objects on the connecting part.
• Check that the fuel tube joint is inserted
securely.
• 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 joint has not been pulled off.
10. INSTALL FUEL TANK TO FILLER PIPE HOSE (See
page FU-44)
A079527E01
A165504
A165004E01
A165008E01
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2GR-FE FUEL – FUEL PUMPFU–37
FU
INSTALLATION
1. INSTALL FUEL TANK ASSEMBLY (See page FU-44)
2. INSPECT FOR FUEL LEAK (See page FU-7)
3. INSTALL FUEL TANK FILLER HOSE COVER (See
page FU-45)
4. INSTALL REAR FLOOR NO. 2 CROSSMEMBER
BRACE LH (See page FU-46)
5. INSTALL CHARCOAL CANISTER PROTECTOR
(a) Install the 6bots and the charcoal canister protector.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)