Toyota FJ Cruiser (GSJ 10, 15 series). Instruction — part 233

1GR-FE FUEL – FUEL TANK

FU–47

FU

15. REMOVE FUEL TANK MAIN TUBE AND RETURN

TUBE
(a) Remove the 2 joint clips, and pull out the 2 fuel tank

tubes.
NOTICE:
•

Check that there is no dirt or mud around the
quick connector before performing this work,
because the quick connector has an O-ring
which seals the pipe and the connector.
Clean the connector if necessary.

•

Do not use any tools in this work.

•

Do not bend or twist the nylon tube by force.

•

After disconnecting, cover the fuel tube joint
with a vinyl bag.

•

When the fuel tube joint and fuel suction plate
are stuck, turn the fuel tank main tube
carefully to free and then disconnect it.
Likewise, disconnect the fuel tank return
tube.

16. REMOVE FUEL SUCTION WITH PUMP AND GAUGE

TUBE ASSEMBLY (See page

FU-29

)

17. DRAIN FUEL

18. REMOVE FUEL TANK BREATHER TUBE SUB-

ASSEMBLY
(a) Pinch the retainer to disengage the lock claws and

pull out the fuel tank breather tube.
NOTICE:
•

Check that there is no dirt or mud around the
quick connector before performing this work,
because the quick connector has an O-ring
which seals the pipe and the connector.
Clean the connector if necessary.

•

Do not use any tools in this work.

•

Do not bend or twist the nylon tube.

•

To protect the tube, cover it with a vinyl bag
after disconnecting it.

•

When the connector and the pipe are stuck,
turn the fuel tank breather tube carefully to
disconnect them.

O-ring

A129915E01

O-ring

Retainer

A129917E01

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1GR-FE FUEL – FUEL TANK

FU

19. REMOVE FUEL TANK TO FILLER PIPE HOSE

(a) Loosen the clamp bolt, and disconnect the fuel tank

to filler pipe hose.

INSTALLATION

1.

INSTALL FUEL TANK TO FILLER PIPE HOSE
(a) Connect a new fuel tank to filler pipe hose, as

shown in the illustration, with the clamp.

2.

INSTALL FUEL TANK BREATHER TUBE SUB-
ASSEMBLY
(a) Push the tube connector into the pipe until the

connector makes a "click" sound and install the
retainer.
NOTICE:
•

Check if there is any damage or foreign
matter on the connected part of the pipe.

•

After connecting, check if the pipe and the
connector are securely connected by pulling
them.

3.

INSTALL FUEL SUCTION WITH PUMP AND GAUGE
TUBE ASSEMBLY (See page

FU-34

)

A138097

A138097

O-ring

Retainer

A129917E04

1GR-FE FUEL – FUEL TANK

FU–49

FU

4.

INSTALL FUEL TANK MAIN TUBE AND FUEL TANK
RETURN TUBE
(a) Install the fuel tank main tube and return tube with

the 2 joint clips.
NOTICE:
•

Check that there are no scratches or foreign
matter around the connected part of the fuel
tube joint and plug before performing this
work.

•

Check that the fuel tube joint is securely
inserted into the end.

•

Check that the tube joint clips are on the
collar of the fuel tube joint.

•

After installing the tube joint clip, check that
the fuel tank main tube and return tube can be
pulled out.

5.

INSTALL FUEL TANK CUSHION
(a) Install 4 new fuel tank cushions the fuel tank.

6.

INSTALL NO.3 FUEL TANK PROTECTOR
(a) Install the No. 3 fuel tank protector with the 2 bolts

and 3 claws.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

O-ring

A138098E01

A129919

A129923

FU–50

1GR-FE FUEL – FUEL TANK

FU

7.

INSTALL FUEL TANK ASSEMBLY
(a) Set a mission jack to the fuel tank.
(b) Install the fuel tank and 2 fuel tank bands with the 2

clips, 2 pins and the 2 bolts.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)

8.

INSTALL FUEL TANK VENT HOSE
(a) Connect the fuel tank vent hose.

(1) Align the fuel tank vent hose connector with the

pipe, then push in the fuel tank vent connector
until the retainer makes a "click" sound to
connect the fuel tank vent hose to the charcoal
canister.
NOTICE:
•

Check that there are no scratches or
foreign matter on the disconnected parts
of the fuel tank vent connector and pipe
before performing the work.

•

After connecting the fuel tank vent hose,
check that the fuel tank vent hose is
securely connected by pulling the quick
connector.

9.

CONNECT FUEL TANK MAIN TUBE AND FUEL TANK
RETURN TUBE
(a) Push the tube connector into the pipe until the

connector makes "click" sound.
NOTICE:
•

Check that there is no damage or foreign
objects on the connected part of the pipe.

•

After connecting, check if the pipe and the
connector are securely connected by pulling
them.

A129914

PUSH

A129912E02

UNLOCK

LOCK

O-Ring

Retainer

A129911E01