Fuel Tank Installation

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

Install the fuel tank breather hose to the fuel tank.

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

Attach the 2 claws to install the protector.

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

Install the fuel suction with pump and gauge 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 suction with pump and gauge tube, tighten the 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. Be sure to use 4 SST (claws) as shown in the illustration.
   
2. Engage SST (claws) securely with the fuel pump gauge retainer ribs to secure SST.
   

While pressing SST (claws) against 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 retainer until the mark on the 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 those specified in this operation. Damage to the fuel pump gauge retainer or 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 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 have not been pulled off.
   

Connect the vent line hose and install the vent line tube.

Install 2 new fuel tank cushions.

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 4 clips and nut.

Torque:

6.0 N*m{61 kgf*cm, 53 in.*lbf}

Set the fuel tank on an engine lifter and lift up the engine lifter.

NOTICE:

1. Do not allow the fuel tank to contact the vehicle, especially the differential.
   
2. Be careful not to cut the wiring.
   

Fold back the 2 cushion rubbers.

Attach the wire harness to the 6 clamps and fuel pump and sender gauge connector.

Install the cushion rubber to the front side with the remaining 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}

Install the fuel tank inlet pipe with the bolt.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

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

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

Connect the fuel tank main tube (HILUX_TGN26 RM000000YL4019X.html).

Connect the fuel tank return tube (HILUX_TGN26 RM000000YL4019X.html).

Connect the vent line hose.

Install the tube clamp to the fuel tube.

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

Torque:

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

Make sure that there are no fuel leaks after performing maintenance on the fuel system.

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON and turn the intelligent tester 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 intelligent tester from the DLC3.