2008 Toyota Land CruiserFACTORY OEM SERVICE PROCEDURE

Fuel Tank: Installation

  1. INSTALL NO. 1 FUEL TANK HEAT INSULATOR 
    1. Install the No. 1 fuel tank heat insulator with the 4 clips.
    2. Install the fuel tube clamp to the No. 1 fuel tank heat insulator.
    Fig 1: Locating Fuel Tank Heat Insulator With Clips
    G05628908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL TANK TO FILLER PIPE HOSE 
    1. Install the fuel tank to filler pipe hose to the fuel tank as shown in the illustration (Fig 2).

      HINT:

      • Align the fuel tank side mark with the hose side mark when installing the hose.
      • Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration (Fig 2).
      Fig 2: Identifying Fuel Tank Mark Location
      G05628909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Apply a light coat of gasoline or grease to a new gasket, and install it to the fuel tank.
      Fig 3: Identifying Hose Clamp
      G05628910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel suction with pump and gauge tube into the fuel tank.
      NOTE:
      • Be careful not to bend the arm of the fuel sender gauge.
      • Align the protrusion of the pump and gauge tube with the groove of the fuel tank.
    3. Put the retainer on the fuel tank. While holding the fuel suction with pump and gauge tube, tighten the retainer 1 complete turn by hand.
      Fig 4: Aligning Protrusion Of Pump And Gauge Tube With Groove Of Fuel Tank
      G05628911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, tighten the retainer until the mark on the retainer is within range A on the fuel tank, as shown in the illustration (Fig 5).

      SST 09808-14020 (09808-01410, 09808-01420, 09808-01430) 

      HINT:

      Fit the tips of SST onto the ribs of the retainer.

      Fig 5: Fitting Tips Of SST Onto Ribs Of Retainer
      G05628912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN TUBE SUB-ASSEMBLY 
    1. Install the 2 fuel tank tubes and No. 1 fuel tube joint with the 3 tube joint clips.
      Fig 6: Locating Fuel Tank Tubes Clips
      G05628913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.