Fuel Tank (For 3 Door) Installation


  1. INSTALL NO. 1 FUEL TANK CUSHION

  2. INSTALL FUEL TUBE GROMMET

  3. INSTALL FUEL TANK FILLER PIPE LOWER SUB-ASSEMBLY

  4. INSTALL FUEL TANK BREATHER HOSE

  5. INSTALL FUEL TANK TO FILLER PIPE HOSE

  6. INSTALL FUEL SENDER GAUGE ASSEMBLY

  7. INSTALL FUEL CUT OFF VALVE ASSEMBLY

  8. INSTALL NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY

  9. INSTALL FUEL SUCTION TUBE ASSEMBLY

  10. INSTALL FUEL TANK SUB-ASSEMBLY

  11. CONNECT FUEL TANK BREATHER HOSE

  12. CONNECT FUEL TANK TO FILLER PIPE HOSE

  13. CONNECT FUEL HOSE

  14. CONNECT FUEL MAIN TUBE

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

  16. INSTALL REAR FLOOR SERVICE HOLE COVER

  17. INSTALL REAR FLOOR MAT SUPPORT PLATE

  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  19. INSPECT FOR FUEL LEAK

Fuel Tank (For 3 Door) -- Installation



1. INSTALL NO. 1 FUEL TANK CUSHION
  1. Install new 2 No. 1 fuel tank cushions to the fuel tank sub-assembly.



2. INSTALL FUEL TUBE GROMMET
  1. Attach the clamp to install the fuel tube grommet.



3. INSTALL FUEL TANK FILLER PIPE LOWER SUB-ASSEMBLY
  1. Install a new gasket and the fuel tank filler pipe lower sub-assembly with the 8 screws.

    Torque:
    3.0 N*m{31 kgf*cm, 27 in.*lbf}


4. INSTALL FUEL TANK BREATHER HOSE
  1. Install the fuel tank breather hose to the fuel tank sub-assembly.



5. INSTALL FUEL TANK TO FILLER PIPE HOSE
  1. Install the fuel tank to filler pipe hose to the fuel tank sub-assembly.



6. INSTALL FUEL SENDER GAUGE ASSEMBLY
  1. Install a new gasket and the fuel sender gauge assembly with the 5 screws.

    Torque:
    1.5 N*m{15 kgf*cm, 13 in.*lbf}
    NOTICE:
    Be careful not to bend the arm of the fuel sender gauge assembly.


7. INSTALL FUEL CUT OFF VALVE ASSEMBLY
  1. Install the fuel cut off valve assembly to the fuel tank sub-assembly.



8. INSTALL NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY
  1. Install a new gasket and the No. 1 fuel evaporation tube sub-assembly with the 4 screws and attach the clamp.

    Torque:
    1.5 N*m{15 kgf*cm, 13 in.*lbf}


9. INSTALL FUEL SUCTION TUBE ASSEMBLY
  1. Install a new gasket and the fuel suction tube assembly with the 7 screws and attach the 2 clamps.

    Torque:
    3.5 N*m{36 kgf*cm, 31 in.*lbf}


10. INSTALL FUEL TANK SUB-ASSEMBLY
  1. Set the fuel tank sub-assembly on an engine lifter and lift up the engine lifter.

  1. Install the 2 fuel tank band sub-assemblies with the 2 pins and 2 clips.

  1. Connect the 2 fuel tank band sub-assemblies with the 2 bolts.

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


11. CONNECT FUEL TANK BREATHER HOSE
  1. Connect the fuel tank breather hose to the filler pipe.



12. CONNECT FUEL TANK TO FILLER PIPE HOSE
  1. Connect the fuel tank to filler pipe hose to the filler pipe.



13. CONNECT FUEL HOSE
  1. Connect the fuel evaporation hose and fuel hose.



14. CONNECT FUEL MAIN TUBE
  1. Connect the fuel main tube (LandCruiser RM0000028RU05IX.html).



15. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
  1. Install the No. 1 fuel tank protector sub-assembly with the 5 bolts.

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


16. INSTALL REAR FLOOR SERVICE HOLE COVER
  1. Connect the fuel sender gauge connector and fuel pump connector.

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



17. INSTALL REAR FLOOR MAT SUPPORT PLATE
  1. Attach the 6 claws to install the rear floor mat rear support plate.

  1. Install the 5 screws.



18. 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).


19. INSPECT FOR FUEL LEAK
  1. Make sure that there are no fuel leaks after performing maintenance on the fuel system.

    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON and turn the GTS on.

      NOTICE:
      Do not start the engine.
    3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

    4. Check that there are no leaks from the fuel system.
      If there are fuel leaks, repair or replace parts as necessary.

    5. Turn the ignition switch off.

    6. Disconnect the GTS from the DLC3.