Fuel Tank Installation

Install the 3 fuel tank protector cushions as shown in the illustration.

Attach the 2 claws to install the No. 2 fuel tank protector.

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

Install the fuel tank breather hose to the fuel tank.

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

Install the fuel tank vent tube to the fuel tank.

NOTICE:

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

Set the fuel pump gauge retainer on the fuel tank. While holding the fuel tank vent tube, tighten the fuel pump gauge retainer one complete turn by hand.

Temporarily install SST (plate and 4 claws) to the fuel pump gauge retainer.

SST

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HINT:

1. Hold the fuel tank vent tube sub-assembly upright by hand to make that the gasket is not moved out of position.
   
2. Be sure to use 4 SST (claws) as shown in the illustration.
   
3. Engage SST (claws) securely with the fuel pump gauge retainer ribs to secure SST.
   

While pressing SST (claws) to the fuel pump gauge retainer ribs securely, install the 4 bolts.

HINT:

Install SST while pressing SST (claws) against the fuel pump gauge retainer (toward the center of SST).

Install SST (handle).

Using SST, tighten the fuel pump gauge retainer until the mark on the fuel pump gauge retainer aligns with mark A on the fuel tank, as shown in the illustration.

SST

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NOTICE:

1. Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.
   
2. Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
   
3. Make sure to rotate SST (handle) horizontally. If SST (handle) is rotated at an angle, SST may come off.
   
4. Do not spin SST too fast or use an impact wrench as this may result in damage to components.
   
5. If SST comes off of the fuel pump gauge retainer, loosen SST (bolts) and reinstall SST.
   

HINT:

1. If the alignment is difficult, make sure the mark on the fuel pump gauge retainer is within range B on the fuel tank.
   
2. Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing SST, rotate the handle slowly to tighten the fuel pump gauge retainer.
   
3. The tips of SST (claws) can be fitted onto the ribs of the fuel pump gauge retainer.
   

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

Install the 2 fuel tank tubes with the 2 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 tube joint clips are on the collars of the fuel tube joints.
   
4. After installing the tube joint clips, check that the fuel tube joints cannot be pulled off.
   

Install the No. 1 fuel evaporation tube to the fuel tank.

Install 2 new fuel tank cushions.

Text in Illustration

*1	Clip
	Fuel Tank Cushion

Install the clip to the cushion on the front side.

HINT:

Install only 1 clip so that the cushion can be folded back and the wire harness can be installed when the fuel tank assembly is installed to the vehicle.

Install the No. 1 fuel tank heat insulator with the 4 clips and nut.

Set the fuel tank on an engine lifter and raise the fuel tank.

NOTICE:

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

Fold back the 2 cushions.

Attach the wire harness to the 6 wire harness clips and connect the fuel sender gauge connector.

NOTICE:

Be careful not to cut the wiring.

Install the clip.

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

Connect the 2 fuel tank bands with the 2 bolts.

Torque:

61 N*m{622 kgf*cm, 45 ft.*lbf}

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

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

Connect the fuel tank main tube and fuel tank return tube.

Install the No. 1 fuel tank protector with the 4 nuts.

Torque:

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

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. Hand pump pumping speed: Max. 2 strokes/ sec.
   
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.
   

Check if the engine starts.

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 to ON and turn the intelligent tester on.

Clear the DTCs.

1. w/ EGR Cooler: (HILUX_TGN26 RM000000PDK0TAX.html)
   
2. w/o EGR Cooler: (HILUX_TGN26 RM000000PDK0SWX.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 fifth 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.

1. w/ EGR Cooler: (HILUX_TGN26 RM000000PDK0TAX.html)
   
2. w/o EGR Cooler: (HILUX_TGN26 RM000000PDK0SWX.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 push the intelligent tester main switch 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.