1. The sub will not pump (whether manually selected or on startup) when the main tank is full. This is so you do not pump fuel out the expansion/overflow outlets onto the ground.
2. The sub will pump approx 1 litre on startup when the main tank level is below approximately 7/8's full (as previously said). It will empty pretty quickly if started frequently.
3. The sub will not pump when down to approximately 2-5 litres left in tank.
4. You can check to see if sub is pumping on startup if you remove main tank filler and start engine. The sub empties into the main filler neck approximately 4-5" down so you can see it.
5. The sub tank is controlled by an ECU and looks at several sensors. The ECU is prone to lock up with certain types of turbo timers due to losing one of the voltage lines.
6. If you get a sub tank light illumination, disconnect the battery first for a few minutes (negative only). This should fix over 90% of the problems. There are earth issues with the sub pump as the chassis is not earthed to the body. Also turbo timers cause the sub tank light to illuminate.
7. You had better hope that you do not have a sub pump failure as they are $800 a pop. If you do, get a bocsh pump and wire it in bypassing the ECU, or
8. Pi$$ the whole system off and put in a Toyota 75/79 series fuel changeover system. That way you can suck fuel from either the main or sub direct to the engine. Very handy if you get a tank of bad fuel. This is something I will be doing if my 3rd sub tank pump fails.
Regards
David