MR2 Fuel Pump Hanger Kit Install time: 2 to 3 hours

Tools: • Socket driver • 7mm socket • 8mm socket • 10mm socket • 11/16" wrench • 7/8" wrench • 17mm wrench • 4mm allen key • Crescent wrench to support bulk head fittings • Wire crimpers • Wire cutters • Heat source for heat shrink connectors

Fuel pump hanger assembly requires removal of: OEM fuel tank from vehicle OEM parking brake assembly OEM coolant lines running from front of vehicle to back OEM under panels Please follow OEM Toyota MR2 service manual for correct procedure.

Instructions: 1. MR2 fuel pump hanger components (Fig 1) 2. Pre-assemble top mount. install hanger gasket to top mount, be sure the alignment tabs are in the correct

location. (Fig 2) 3. Install bulk head fittings to top mount. Lubricate O-rings prior to installation, tighten bulk head fittings using

7/8” wrench. (Fig 3-5) 4. Pre assemble fuel pump mount. Lubricate O-rings, and completely seat in O-ring grooves. (Fig 6 & 7) 5. Assemble fuel pump mount to hanger rod. Seat hanger rod completely to fuel pump mount. Install M6 short

button head with lock washer using 4mm allen key. (Fig 8 & 9) 6. Finish fuel pump hanger assembly. Install M10 bolt with lock washer and flat washer using 17mm wrench. Be

sure to align top mount with fuel pump mount. Tip: Use bench vise to hold fuel pump mount while tightening M10 bolt. (Fig 10 & 11)

7. Pre-assemble push lock fittings, to fuel hose. Completely seat fitting into fuel hose, lightly lubricate fittings to ease installation. Tighten clamps with 7mm socket. (Fig 12 & 13)

8. Prep fuel pump. Cut electrical connector from power and ground wires. Leave wires as long as possible. Crimp electrical connectors and apply heat to secure connectors. Install fuel sock (for new fuel pumps). (Fig 14)

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9. Install fuel pump to fuel pump mount. For 450LPH pump completely seat fuel pump to bottom. For 255LPH pump leave 1 inch from bottom of fuel pump mount. (Tip: Note orientation of fuel pump, the filter sock should be facing toward hanger rod) (Fig 15 & 16)

10. Install grounding wire to hanger rod. Use short M6 bolt and washer to secure grounding wire. Tip: make sure grounding wire is touching rod grounding location. (Fig 17 & 18)

11. Tighten fuel pump to fuel pump mount. Insert M6 long button head through front of mount, and thread M6 deformed nut. Tighten using 4mm allen key and 10mm open end wrench. Do not over tighten, pump should not rotate in mount. (Fig 19 & 20)

12. Install fuel hose lines to pump and bulk head fittings. Install fuel feed line to pump, then carefully thread onto bulk head fitting. Install fuel return line. Tighten fittings use 11/16 open end wrench, hold bulk head fittings to prevent rotation (do not over tighten fittings, they seal on face). Tighten clamps using 7mm socket and secure fuel return line to hanger rod using zip tie. (Fig 21 & 22)

13. Remove OEM fuel pump hanger assembly. Unbolt fuel lines from fuel tank using 10mm socket. Unbolt fuel pump hanger assembly from tank using 8mm socket. Cut power and ground wires from hanger assembly, they will be re-used. Remove hanger assembly and lines from fuel tank. (Fig 23 & 24)

14. Install +12V power wire to fuel pump hanger assembly. Crimp wire connectors and apply heat to ground and power wires. Install Long M6 bolt with teflon washers, flat washers, and lock washers. Tighten using 10mm socket / wrench. Tip: Note placement of teflon washers, and flat washers. Incorrect installation can cause fuel pump to not function. M6 Bolt - +12V wire - flat washer - Teflon shoulder washer/O-ring - Top mounting plate - Teflon washer - Stainless Steel spacer - Larger flat washer - +12V wire - Loc washer - M6 Nut (Fig 25 & 26)

15. Install fuel pump hanger assembly to fuel tank. Install 3 of the 5 M5 allen head bolts, do not tighten. (Fig 27) 16. Install fuel pump hanger assembly to fuel tank. Move OEM fuel line tab to new location and install M5 bolt.

Install grounding wire with M5 bolt, loc washer and flat washer. Tighten M5 bolts with 4mm allen key. Tip: Wiring cover may have to be cut back to allow wiring to move freely. (Fig 28)

Questions, comments, or concerns? Email tech@racerxfabrication.com.

© 2016 Racer X Fabrication

© 2016 Racer X Fabrication

© 2016 Racer X Fabrication

© 2016 Racer X Fabrication

© 2016 Racer X Fabrication

© 2016 Racer X Fabrication