Fuel Tank Installation


  1. INSTALL FUEL TANK TO FILLER PIPE HOSE

  2. INSTALL NO. 3 FUEL TANK PROTECTOR

  3. INSTALL FUEL TANK VENT TUBE ASSEMBLY

  4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL RETURN TUBE SUB-ASSEMBLY (for Single Tank Type)

  5. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL RETURN TUBE SUB-ASSEMBLY (for Double Tank Type)

  6. INSTALL FUEL TANK CUSHION

  7. INSTALL FUEL TANK SUB-ASSEMBLY

  8. CONNECT FUEL TANK TO FILLER PIPE HOSE

  9. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Single Tank Type)

  10. CONNECT FUEL CUT OFF TUBE (for Single Tank Type)

  11. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Double Tank Type)

  12. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY (for Double Tank Type)

  13. CONNECT FUEL CUT OFF TUBE (for Double Tank Type)

  14. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY (for Single Tank Type)

  15. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Single Tank Type)

  16. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)

  17. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

  18. INSTALL REAR FLOOR SERVICE HOLE COVER

  19. INSTALL REAR SEAT ASSEMBLY LH

  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  21. BLEED AIR FROM FUEL SYSTEM

  22. INSPECT FOR FUEL LEAK

Fuel Tank -- Installation



1. INSTALL FUEL TANK TO FILLER PIPE HOSE


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.5L-E Fuel.Fuel System.Fuel Tank Installation

  1. Align the fuel tank side mark with the hose side mark.

    Text in Illustration
    *1
    		Fuel Tank Side Mark
    *2
    		Hose Side Mark

  1. Install the fuel tank to filler pipe hose to the fuel tank.



2. INSTALL NO. 3 FUEL TANK PROTECTOR

  1. Install the No. 3 fuel tank protector and attach the 4 clamps.

  1. Install the 2 bolts.

    Torque:
    5.0 N*m{51 kgf*cm, 44 in.*lbf}


3. INSTALL FUEL TANK VENT TUBE ASSEMBLY

  1. Apply a light coat of gasoline or grease to a new gasket and install the gasket to the fuel tank.



    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.5L-E Fuel.Fuel System.Fuel Tank Installation

  1. Align the protrusion of the fuel tank vent tube with the groove of the fuel tank.

    Text in Illustration
    *1
    		Protrusion
    *2
    		Groove
    NOTICE:
    Be careful not to bend the arm of the fuel sender gauge.

  1. Install the fuel tank vent tube to the fuel tank.



  1. Put a new retainer on the fuel tank. While holding the fuel tank vent tube, tighten the retainer one complete turn by hand.

    Text in Illustration
    *1
    		Start Mark (Fuel Tank Side)
    *2
    		Start Mark (Retainer Side)

    HINT:
    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.5L-E Fuel.Fuel System.Fuel Tank Installation
    Make sure the start marks on the retainer and fuel tank are aligned, and then tighten the retainer.


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.5L-E Fuel.Fuel System.Fuel Tank Installation

  1. Set SST on the retainer.

    SST
    09808-14030
    HINT:
    1. Hold the fuel tank vent tube assembly upright by hand to ensure that the gasket is not moved out of position.
    2. Engage the claws of SST securely with the retainer holes to secure SST.
    3. Install SST while pressing the claws of SST against the retainer (toward the center of SST).


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.5L-E Fuel.Fuel System.Fuel Tank Installation

  1. Using SST, tighten the retainer until the mark on the retainer is within range A on the fuel tank as shown in the illustration.

    SST
    09808-14030
    Text in Illustration
    *1
    		Fuel Tank Side Mark
    *2
    		Retainer Side Mark
    HINT:
    Fit the tips of SST onto the ribs of the retainer.


4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL RETURN TUBE SUB-ASSEMBLY (for Single Tank Type)


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Install the fuel tank main tube and fuel return tube with the 2 fuel tube joint clips.

    NOTICE:

    1. Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.5L-E Fuel.Fuel System.Fuel Tank Installation
      Check that there are no scratches or foreign objects on the connecting parts.
    2. Check that the fuel tube joints are inserted securely.
    3. Check that the fuel tube joint clips are on the collars of the fuel tube joints.
    4. After installing the fuel tube joint clips, check that the fuel tube joints cannot be pulled off.
      Text in Illustration
      *1
      		Fuel Tube Joint
      *2
      		O-Ring
      *3
      		Fuel Tube
      *4
      		Fuel Tube Joint Clip
      *a
      		CORRECT
      *b
      		INCORRECT

  1. Install the fuel tank main tube and fuel return tube to the fuel tank.



5. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL RETURN TUBE SUB-ASSEMBLY (for Double Tank Type)


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Install the fuel tank main tube and fuel return tube with the 2 fuel tube joint clips.

    NOTICE:

    1. Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.5L-E Fuel.Fuel System.Fuel Tank Installation
      Check that there are no scratches or foreign objects on the connecting parts.
    2. Check that the fuel tube joints are inserted securely.
    3. Check that the fuel tube joint clips are on the collars of the fuel tube joints.
    4. After installing the fuel tube joint clips, check that the fuel tube joints cannot be pulled off.
      Text in Illustration
      *1
      		Fuel Tube Joint
      *2
      		O-Ring
      *3
      		Fuel Tube
      *4
      		Fuel Tube Joint Clip
      *a
      		CORRECT
      *b
      		INCORRECT

  1. Install the fuel tank main tube to the fuel tank.

  1. Install the fuel return tube to the fuel tank and attach the clamp.



6. INSTALL FUEL TANK CUSHION

  1. Install 3 new fuel tank cushions to the fuel tank.



7. INSTALL FUEL TANK SUB-ASSEMBLY

  1. Set the fuel tank on a transmission jack and rise the transmission jack.

    NOTICE:
    Do not allow the fuel tank to contact the vehicle, especially the differential.

  1. Install the 2 fuel tank bands with the 2 pins and 2 clips.

  1. Connect the 2 fuel tank bands with the 2 bolts.

    Torque:
    40 N*m{408 kgf*cm, 30 ft.*lbf}


8. CONNECT FUEL TANK TO FILLER PIPE HOSE

  1. Connect the fuel tank to filler pipe hose to the filler pipe.



9. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Single Tank Type)

  1. Connect the fuel tank breather tube (LandCruiser RM0000047AH005X.html).



10. CONNECT FUEL CUT OFF TUBE (for Single Tank Type)


11. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Double Tank Type)

  1. Connect the fuel tank breather tube (LandCruiser RM0000047AH005X.html).



12. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY (for Double Tank Type)

  1. Connect the fuel return tube (LandCruiser RM0000047AH005X.html).



13. CONNECT FUEL CUT OFF TUBE (for Double Tank Type)

  1. Connect the fuel cut off tube (LandCruiser RM0000047AH005X.html).



14. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY (for Single Tank Type)


15. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Single Tank Type)


16. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)


17. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

  1. Install the No. 1 fuel tank protector with the 6 bolts.

    Torque:
    20 N*m{204 kgf*cm, 15 ft.*lbf}


18. INSTALL REAR FLOOR SERVICE HOLE COVER

  1. Connect the fuel sender gauge connector.

  1. Install the rear floor service hole cover with the 3 screws.



19. INSTALL REAR SEAT ASSEMBLY LH

  1. for 60/40 Split Double-folding Seat Type LH Side:
    Install the rear seat assembly LH (LandCruiser RM00000468N00TX.html).

  1. for 60/40 Split Slide Walk-in Seat Type LH Side:
    Install the rear seat assembly LH (LandCruiser RM00000468800TX.html).



20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected (LandCruiser RM000003YMF011X.html).


21. BLEED AIR FROM FUEL SYSTEM


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.



22. INSPECT FOR FUEL LEAK

  1. Check that there are no fuel leaks anywhere in the fuel system after performing maintenance.

    HINT:
    When checking for fuel leaks, make sure that there is pressure in the fuel line.