Toyota 23280-21010
Fuel Pressure Regulator

The first step when servicing the 2ZR-FE engine fuel pressure regulator is to discharge fuel system pressure. The service procedure starts with fuel pump removal through proper operational steps. The pressure regulator removal process starts with a taped screwdriver tip which you must use carefully. Finish by removing all two O-rings present in the pressure regulator assembly.

You need to place gasoline on two new O-rings before installing them onto the fuel pressure regulator assembly when performing installation for the 2ZR-FE engine. After installing two new O-rings on the fuel pressure regulator assembly you will install the regulator itself. Install the fuel pump by following standard procedures for fuel pump servicing and repair afterwards. The last step includes leak inspection for fuel while respecting all safety protocols during service operations.

The 2AZ-FE engine requires discharging fuel system pressure before you begin the process of removing the fuel pressure regulator. Drain the fuel while following the steps of disconnecting the cable from the negative battery terminal. Proper procedures should be followed to remove the fuel pump before the next steps. To proceed with the fuel pressure regulator removal you must use a screwdriver protected by tape to remove the assembly. The removal process requires discarding the two rubber O-rings present in the pressure regulator assembly.

Before removing the fuel pressure regulator assembly on the 2AZ-FE engine model it is necessary to discharge fuel system pressure. You must first disconnect the negative cable before extracting the fuel suction tube assembly from the fuel tank component. The removal sequence for 4WD fuel components starts with taking out the fuel sender gauge assembly and then proceeds to the fuel pump after releasing its claw to detach the fuel pump filter hose and separating the claw at the jet pump nozzle while using a wrapped screwdriver to safely extract the jet pump and O-ring. To remove the fuel pump sub-tank use 2 claws but preserve the wire harness during the process of disconnecting the fuel pump harness connector. First remove the No. 1 fuel suction support along with the suction filter and fuel pump from the fuel filter while being cautious to avoid fuel pump filter or fuel filter damage yet avoiding suction filter removal. The O-ring should be removed from the fuel pump after disconnecting its connector. 2WD versions require the same procedure for fuel pump removal by releasing the claw before disconnection of harnesses and suction filter removal without inducing any damage. The removal process of the fuel pressure regulator assembly requires a screwdriver with tape protection on its tip to pull it slowly because it has a tightly installed O-ring and separation of the 2 O-rings from the assembly.

The installation process of fuel pressure regulator assembly for 2ZR-FE requires applying gasoline to two new O-rings before placing them on the regulator assembly. After that install the Fuel Pressure Regulator Assembly. After the fuel pump install the system requires the driver to mount the fuel sender gauge assembly. The motorist must install both fuel suction tube assembly along with pump and gauge to the fuel tank next. You must check the fuel system for leakage before connecting the cable to the negative battery terminal.

The first step in fuel pressure regulator replacement involves installing the fuel suction with pump and gauge tube assembly followed by application of a new fuel suction tube gasket on the fuel tank while keeping the sender gauge arm from deformation. The installation process requires turning the fuel pump gauge retainer 540 degrees clockwise from the screw starting point using Special Service Tool: 09808-14020 until the claw of the retainer aligns with the matchmark on the fuel tank followed by retainer replacement unless previously installed. Run the fuel tank vent hose sub-assembly followed by inserting the main fuel tank tube while securing it with a tube joint clip during inspection of connectable parts and tube joint security. Checking the fuel tube joint requires verification of proper joint position and the replacement of damaged tube joint clips. Mount the rear service hole cover after you connect the fuel pump connector while also applying new butyl tape. In hatchback models the required components include rear seat assembly installation followed by rear seat leg cover application and deck floor box installation. You should also mount the deck board sub-assembly and package tray trim panel assembly. The installation of rear seat cushion cover pads should be done on sedan models. The negative terminal cable connection requires a torque of 5.4 Nm (55 kgf-cm, 48 in-lbf) before inspecting for fuel leakages.

First discharge the fuel system pressure.

Install the fuel pressure regulator assembly.

Inspect for any fuel leaks.

Install the damper using 2 bolts, ensuring a torque of 9.0 Nm (90 kgf-cm, 80 in-lbf) while checking that the O-ring is not cracked or jammed.

Remove the rear seat cushion assembly and the rear floor service hole cover.

Finally, remove the 2 O-rings from the pressure regulator assembly.

Place a new gasket on the fuel suction tube and install it, ensuring not to damage the fuel pump filter or bend the sender gauge arm.

Inspect for any fuel leaks, ensuring all service precautions are observed.

Take out the 2 O-rings from the pressure regulator assembly.

Remove the E-ring, release the claw to take out the fuel pump filter, and then remove the fuel suction plate and spring.

Apply gasoline to two new O-rings and install them onto the fuel pressure regulator assembly before securing the assembly in place.

Take out the E-ring and release the claws to remove the fuel pump filter and suction plate.

Remove the 2 O-rings from the fuel pressure regulator assembly.

Install the fuel pressure regulator to the fuel filter.

Install the air cleaner cap sub-assembly.

Apply a light coat of gasoline to 2 new O-rings and install them onto the fuel pressure regulator before attaching it to the fuel filter.

Detach the 2 claws using a screwdriver, ensuring to tape the screwdriver tip beforehand.

Fully tighten the No. 1 surge tank stay and the throttle body bracket.

Install the fuel sender gauge assembly for either 4WD or 2WD.

Remove the fuel pressure regulator assembly from the fuel filter and take off the 2 O-rings from the fuel pressure regulator.

Install the fuel pressure regulator to the fuel filter.

Disconnect its connector and slide it out.

Install the fuel tube with the tube joint clip, checking for scratches or foreign objects on the connecting parts, ensuring the fuel tube joint is securely inserted, the clip is on the collars, and that the joint has not been pulled off after installation.

Disconnect the wire harness and use needle nose pliers to remove the E-ring from the fuel sub-tank assembly.

Insert the fuel tank main tube, ensuring no scratches or foreign matter are present, and that the tube joint clip is securely installed.

Use a "Torx" socket wrench E10 to remove the rear seat cushion cover pad for either the hatchback or sedan models.

Use a wire tip (dia1 mm) to remove it.

Remove the package tray trim panel assembly and deck board sub-assembly for the hatchback.

Install the fuel sender gauge.