Installation

4GR-FSE FUEL: FUEL PUMP: 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 the O-ring and jet pump to the fuel relief valve assembly.

3. INSTALL FUEL RELIEF VALVE ASSEMBLY

(a) Apply a light coat of gasoline to a new O-ring, and install the O-ring and fuel relief valve assembly 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 and flange assembly to the fuel filter.

5. INSTALL FUEL PUMP

(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) Install the fuel pump to the fuel filter.

(d) Connect the 2 connectors and terminal.

6. INSTALL NO. 1 FUEL SUB-TANK

(a) Apply a light coat of gasoline to a new O-ring, and install the O-ring and No. 1 fuel sub-tank to the fuel filter with flange assembly.

(b) Connect the jet pump nozzle to the No. 1 fuel sub-tank.

7. INSTALL FUEL SENDER GAUGE ASSEMBLY

(a) Set the fuel sender gauge to the No. 1 fuel 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 TUBE ASSEMBLY

(a) Install a new gasket onto the fuel tank.

(b) Connect the fuel hose with the clip.

(c) Set the fuel suction tube to the fuel tank.

NOTICE:
* Make sure that the fuel sender gauge arm does not bend.
* Do not damage the No. 2 fuel hose.
(d) Align the protrusion of the fuel suction tube and the cutout of the fuel tank vent tube set plate.

(e) While holding the fuel suction tube by hand, install the fuel tank vent tube to the fuel tank with the 8 bolts.

Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)

(f) Connect the fuel tube.

(1) Push the fuel tube joint in the plug of the fuel suction plate, then install the 2 tube joint clips.

NOTICE:
* Check that there are no scratches or foreign objects on the connecting parts.
* Check that the fuel tube joint is inserted securely.
* Check that the tube joint clips are on the collars of the fuel tube joints.
* After installing the tube joint clips, check that the fuel tube joints have not been pulled off.
* Be careful not to damage any clips. If a clip is damaged, replace it.
(g) Connect the fuel suction tube connector.

9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation

10. INSPECT FOR FUEL LEAK Testing and Inspection

11. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER

(a) Install the No. 2 rear floor service hole cover with new butyl tape.

12. INSTALL REAR SEAT CUSHION ASSEMBLY Installation