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

FU–48

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