Fuel Tank (For 5 Door) Installation

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

Install the fuel tank to filler pipe hose to the fuel tank sub-assembly, and tighten the clamp to secure the hose.

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

Install the 2 bolts.

Torque:

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

Apply a light coat of diesel fuel or grease to a new gasket and install the gasket to the fuel tank sub-assembly.

Align the protrusion of the fuel tank vent tube assembly with the groove of the fuel tank sub-assembly.

NOTICE:

Be careful not to bend the arm of the fuel sender gauge assembly.

Install the fuel tank vent tube assembly to the fuel tank sub-assembly.

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

HINT:

Make sure the start marks on the retainer and fuel tank sub-assembly are aligned and then tighten the retainer.

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).
   

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

HINT:

Fit the tips of SST onto the ribs of the retainer.

Apply a light coat of diesel fuel or grease to a new gasket and install the gasket to the fuel tank sub-assembly.

Align the protrusion of the fuel suction with pump and gauge tube assembly with the groove of the fuel tank sub-assembly.

NOTICE:

Be careful not to bend the arm of the fuel sender gauge assembly.

Install the fuel suction with pump and gauge tube assembly to the fuel tank sub-assembly.

Put a new retainer on the fuel tank sub-assembly. While holding the fuel suction with pump and gauge tube assembly, tighten the retainer one complete turn by hand.

HINT:

Make sure the start marks on the retainer and fuel tank sub-assembly are aligned and then tighten the retainer.

Set SST on the retainer.

SST

09808-14030

HINT:

1. Hold the fuel suction with pump and gauge 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).
   

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

SST

09808-14030

HINT:

Fit the tips of SST onto the ribs of the retainer.

Install the fuel return tube sub-assembly and fuel tank main tube sub-assembly with the 2 fuel tube joint clips.

NOTICE:

1. 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

Install the fuel return tube sub-assembly and fuel tank main tube sub-assembly to the fuel tank sub-assembly.

Install the fuel tank main tube sub-assembly, fuel return tube sub-assembly and No. 2 fuel main tube sub-assembly with the 3 fuel tube joint clips.

NOTICE:

1. 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

Install the fuel tank main tube sub-assembly to the fuel tank sub-assembly.

Install the fuel return tube sub-assembly to the fuel tank sub-assembly and attach the clamp.

Install the No. 2 fuel main tube sub-assembly to the fuel tank sub-assembly and attach the clamp.

Install the No. 4 fuel main tube sub-assembly and fuel suction tube sub-assembly with the 2 fuel tube joint clips.

NOTICE:

1. 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

Install the fuel suction tube sub-assembly to the fuel tank sub-assembly and attach the clamp.

Install the No. 4 fuel main tube sub-assembly to the fuel tank sub-assembly and attach the clamp.

Install 3 new fuel tank cushions to the fuel tank sub-assembly.

Set the fuel tank sub-assembly on a transmission jack and lift up the transmission jack.

NOTICE:

Do not allow the fuel tank sub-assembly to contact the vehicle, especially the differential.

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

Connect the 2 fuel tank bands with the 2 bolts.

Torque:

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

Connect the fuel tank to filler pipe hose to the filler pipe, and tighten the clamp to secure the hose.

Connect the fuel tank breather tube sub-assembly (LandCruiser RM0000028RU05SX.html).

Connect the fuel cut off tube (LandCruiser RM0000028RU05SX.html).

Connect the fuel tank breather tube sub-assembly (LandCruiser RM0000028RU05SX.html).

Connect the fuel return tube sub-assembly and No. 2 fuel main tube sub-assembly (LandCruiser RM0000028RU05SX.html).

Connect the fuel cut off tube (LandCruiser RM0000028RU05SX.html).

Connect the No. 4 fuel main tube sub-assembly and fuel suction tube sub-assembly (LandCruiser RM0000028RU05SX.html).

Connect the fuel return tube sub-assembly (LandCruiser RM0000028RU05SX.html).

Connect the fuel tank main tube sub-assembly (LandCruiser RM0000028RU05SX.html).

Connect the fuel tank main tube sub-assembly (LandCruiser RM0000028RU05SX.html).

for Type A:

1. Install the No. 1 fuel tank protector sub-assembly with the 6 bolts.
   

   Torque:

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

for Type B:

1. Install the No. 1 fuel tank protector sub-assembly with the 4 bolts.
   

   Torque:

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

Connect the fuel pump and fuel sender gauge connector.

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

for 60/40 Split Double-folding Seat Type LH Side:
(LandCruiser RM00000468N00TX.html).

for 60/40 Split Slide Walk-in Seat Type LH Side:
(LandCruiser RM00000468800TX.html).