INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL RETURN TUBE SUB-ASSEMBLY (for Single Tank Type)
CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Single Tank Type)
CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Double Tank Type)
CONNECT NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)
Fuel Tank (For 5 Door) -- Installation |
| 1. INSTALL FUEL TANK TO FILLER PIPE HOSE |
Align the fuel tank sub-assembly side mark with the hose side mark.
Text in Illustration *a Fuel Tank Sub-assembly Side Mark *b Hose Side Mark
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Install the fuel tank to filler pipe hose to the fuel tank sub-assembly.
| 2. INSTALL NO. 3 FUEL TANK PROTECTOR |
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}
| 3. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY |
Apply a light coat of gasoline 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.
Text in Illustration *a Protrusion *b Groove - NOTICE:
- Be careful not to bend the arm of the fuel sender gauge assembly.
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Install the fuel suction with pump and gauge tube assembly to the fuel tank sub-assembly.
Put a new fuel pump gauge 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 fuel pump gauge retainer and fuel tank sub-assembly are aligned and then tighten the fuel pump gauge retainer.
Text in Illustration *a Start Mark (Fuel Tank Sub-assembly Side) *b Start Mark (Fuel Pump Gauge Retainer Side)
Set SST on the fuel pump gauge retainer.
- SST
- 09808-14030(09808-01030,09808-01040)
- HINT:
- Hold the fuel suction with pump and gauge tube assembly upright by hand to ensure that the fuel suction tube gasket in not moved out of position.
- Engage the claws of SST securely with the fuel pump gauge retainer holes to secure SST.
- Install SST while pressing the claws of SST against the fuel pump gauge retainer (toward the center of SST).
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Using SST, tighten the fuel pump gauge retainer until the mark on the fuel pump gauge retainer is within range A on the fuel tank sub-assembly as shown in the illustration.
- SST
- 09808-14030(09808-01010)
Text in Illustration *a Fuel Tank Sub-assembly Side Mark *b Fuel Pump Gauge Retainer Side Mark - HINT:
- Fit the tips of SST onto the ribs of the fuel pump gauge retainer.
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| 4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL RETURN TUBE SUB-ASSEMBLY (for Single Tank Type) |
Install the fuel tank main tube sub-assembly and fuel return tube sub-assembly with the 2 fuel tube joint clips.
- NOTICE:
Check that there are no scratches or foreign objects on the connecting parts.
- Check that the fuel tube joints are inserted securely.
- Check that the fuel tube joint clips are on the collars of the fuel tube joints.
- After installing the fuel tube joint clips, check that the fuel tube joints cannot be pulled off.
Text in Illustration *a Fuel Tube Joint *b O-Ring *c Fuel Tube *d Fuel Tube Joint Clip *e CORRECT *f INCORRECT
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Install the fuel tank main tube sub-assembly and fuel return tube sub-assembly to the fuel tank sub-assembly.
| 5. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY, FUEL RETURN TUBE SUB-ASSEMBLY AND NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY (for Double Tank Type) |
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:
Check that there are no scratches or foreign objects on the connecting parts.- Check that the fuel tube joints are inserted securely.
- Check that the fuel tube joint clips are on the collars of the fuel tube joints.
- After installing the fuel tube joint clips, check that the fuel tube joints cannot be pulled off.
Text in Illustration *a Fuel Tube Joint *b O-Ring *c Fuel Tube *d Fuel Tube Joint Clip *e CORRECT *f INCORRECT
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Install the fuel tank main tube sub-assembly and fuel return tube sub-assembly to the fuel tank sub-assembly.
Install the No. 2 fuel main tube sub-assembly to the fuel tank sub-assembly and attach the clamp.
| 6. INSTALL FUEL TANK CUSHION |
Install 3 new fuel tank cushions to the fuel tank sub-assembly.
| 7. INSTALL FUEL TANK SUB-ASSEMBLY |
Set the fuel tank sub-assembly on an engine lifter and lift up the engine lifter.
- NOTICE:
- Do not allow the fuel tank sub-assembly to contact the vehicle, especially the differential.
Install the 2 fuel tank band sub-assemblies with the 2 pins and 2 clips.
Connect the 2 fuel tank band sub-assemblies with the 2 bolts.
- Torque:
- 40 N*m{408 kgf*cm, 30 ft.*lbf}
| 8. CONNECT FUEL TANK TO FILLER PIPE HOSE |
Connect the fuel tank to filler pipe hose to the filler pipe.
| 9. CONNECT FUEL CUT OFF TUBE (for Single Tank Type) |
Connect the fuel cut off tube (LandCruiser RM0000028RU05IX.html).
| 10. CONNECT FUEL CUT OFF TUBE (for Double Tank Type) |
Connect the fuel cut off tube (LandCruiser RM0000028RU05IX.html).
| 11. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Single Tank Type) |
Connect the fuel tank breather tube sub-assembly (LandCruiser RM0000028RU05IX.html).
| 12. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Double Tank Type) |
Connect the fuel tank breather tube sub-assembly (LandCruiser RM0000028RU05IX.html).
| 13. CONNECT NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY (for Double Tank Type) |
Connect the No. 2 fuel main tube sub-assembly (LandCruiser RM0000028RU05IX.html).
| 14. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY |
Connect the fuel return tube sub-assembly (LandCruiser RM0000028RU05IX.html).
| 15. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY |
Connect the fuel tank main tube sub-assembly (LandCruiser RM0000028RU05IX.html).
| 16. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY |
Install the No. 1 fuel tank protector sub-assembly with the 6 bolts.
- Torque:
- 20 N*m{204 kgf*cm, 15 ft.*lbf}
| 17. INSTALL REAR FLOOR SERVICE HOLE COVER |
Connect the fuel pump and fuel sender gauge connector.
Install the rear floor service hole cover with the 3 screws.
| 18. INSTALL REAR SEAT ASSEMBLY LH |
- 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)
| 19. 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).
| 20. INSPECT FOR FUEL LEAK |
Make sure that there are no fuel leaks after performing maintenance on the fuel system.
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
- NOTICE:
- Do not start the engine.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
Check that there are no leaks from the fuel system.
If there are fuel leaks, repair or replace parts as necessary.Turn the ignition switch off.
Disconnect the GTS from the DLC3.