Installation
2ZR-FXE FUEL: FUEL PUMP: INSTALLATION
1. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
(a) Install a new fuel suction tube set gasket onto the fuel tank as shown in the illustration.
Text in Illustration
(b) Set the fuel suction tube assembly with pump and gauge to the fuel tank.
Text in Illustration
NOTICE:
Make sure that the fuel sender gauge arm does not bend.
(c) Align the protrusions of the fuel suction tube assembly with pump and gauge with the notches of the fuel tank.
2. INSTALL FUEL PUMP GAUGE RETAINER
(a) While holding the fuel suction tube assembly with pump and gauge by hand to prevent it from tilting, align the mark on the new fuel pump gauge retainer with the start mark on the fuel tank and tighten the fuel pump gauge retainer 180° by hand.
Text in Illustration
HINT
* Check that there is no damage, dents, foreign matter or other defects on the threads of the fuel tank.
(b) Temporarily install the SST plate and claws to the fuel pump gauge retainer.
Text in Illustration
SST : 09808-14030
09808-01030
09808-01040
09808-01050
HINT
Engage the SST claws securely with the fuel pump gauge retainer ribs to secure SST.
(c) While pressing the claws of SST to the fuel pump gauge retainer ribs securely, tighten the bolts.
HINT
Install SST while pressing the SST claws toward the fuel pump gauge retainer (toward the center of SST).
(d) Install the SST handle.
(e) Tighten the fuel pump gauge retainer approximately 360° so that the mark on the retainer comes within the range shown in the illustration.
Text in Illustration
SST : 09808-14030
09808-01010
09808-01020
09808-01030
09808-01040
09808-01050
NOTICE:
* Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.
* Do not press down on SST excessively as this may make the retainer hard to rotate, and may damage components.
* Make sure to rotate the SST handle horizontally. If the SST handle is rotated at an angle, SST may come off.
* Do not spin SST too fast or use an impact wrench as this may result in damage to components.
* If SST comes off of the retainer, loosen the SST bolts and reinstall SST.
HINT
* Lightly press down on SST to prevent it from separating from the retainer. While pressing SST, rotate the handle slowly to tighten the retainer.
* The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.
3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.
Text in Illustration
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 to the end.
* 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 tank main tube cannot be pushed out.
(b) Connect the fuel pump connector.
4. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.
5. INSPECT FOR FUEL LEAK Fuel System
6. INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Install the rear floor service hole cover with new butyl tape.
7. INSTALL REAR SEAT CUSHION LOCK HOOK Installation
8. INSTALL REAR SEAT CUSHION ASSEMBLY Installation
9. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE Installation
10. INSTALL DECK FLOOR BOX RH Installation
11. INSTALL REAR NO. 3 FLOOR BOARD Installation
12. INSTALL REAR DECK FLOOR BOX Installation
13. INSTALL REAR NO. 2 FLOOR BOARD Installation