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.

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 gasoline or grease to a new gasket and install the gasket to the fuel tank.

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

NOTICE:

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

Install the fuel tank vent tube to the fuel tank.

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

HINT:

Make sure the start marks on the retainer and fuel tank 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 gasoline or grease to a new gasket and install the gasket to the fuel tank.

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

NOTICE:

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

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

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

HINT:

Make sure the start marks on the retainer and fuel tank 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 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 and fuel tank main tube 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 and fuel tank main tube to the fuel tank.

Install the fuel tank main tube, fuel return tube and No. 2 fuel main tube 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 to the fuel tank.

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

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

Install the No. 4 fuel main tube and fuel suction tube 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 to the fuel tank and attach the clamp.

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

Install 3 new fuel tank cushions to the fuel tank.

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

NOTICE:

Do not allow the fuel tank 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.

Connect the fuel tank breather tube (LandCruiser RM0000028RU05KX.html).

Connect the fuel tank breather tube (LandCruiser RM0000028RU05KX.html).

Connect the fuel return tube and No. 2 fuel main tube (LandCruiser RM0000028RU05KX.html).

Connect the fuel cut off tube (LandCruiser RM0000028RU05KX.html).

Connect the No. 4 fuel main tube and fuel suction tube (LandCruiser RM0000028RU05KX.html).

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

Torque:

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

for Half Cover Type:
Install the No. 1 fuel tank protector 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:
Install the rear seat assembly LH (LandCruiser RM00000468N00TX.html).

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

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

NOTICE:

1. The maximum hand pump pumping speed is 2 strokes per second.
   
2. The hand pump must be pushed with a full stroke during pumping.
   
3. When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.
   
4. If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.
   
5. If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.
   
6. If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use and the engine cannot be started.
   

Start the engine.

NOTICE:

1. Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.
   
2. Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
   
3. Use a fully-charged battery.
   

1. When the engine can be started, proceed to the next step.
   

2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.
   

Turn the ignition switch off.

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG) and turn the intelligent tester on.

Clear the DTCs (LandCruiser RM000000PDK1DJX.html).

Start the engine.*1

Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.

HINT:

When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

Enter the following menus: Powertrain / Engine and ECT / DTC.

Read Current DTCs.

Clear the DTCs (LandCruiser RM000000PDK1DJX.html).

HINT:

It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

Repeat steps *1 to *3.

Enter the following menus: Powertrain / Engine and ECT / DTC.

Read Current DTCs.

OK:

No DTCs are output.

Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.

Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.

Disconnect the return hose from the common rail.

Start the engine and check for fuel leaks from the return pipe.
If there is fuel leakage, replace the common rail.

Connect the intelligent tester to the DLC3.

Start the engine and turn the intelligent tester on.

Select the Fuel Leak test from the Active Test mode on the intelligent tester.

If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.

Check that there are no leaks from any part of the fuel system.

NOTICE:

A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

Reconnect the return hose to the common rail.