TOYOTA LAND CRUISER 1998 Factory Repair Manual

SF0OZ-15
B16457
Location of Fuel Tank Cushion Fuel Return Hose
Fuel Inlet Pipe Fuel Tank Cap
Cutoff
ValveRing
1.5 (15, 13 in.´lbf)
Fuel Inlet Pipe Protector Fuel Inlet Pipe Shield
 Gasket
3.5 (35, 31 in.´lbf)
 Gasket
Fuel Tank WireFuel Inlet Hose
Fuel Tank
Protector
Fuel Tank Band
N´m (kgf´cm, ft´lbf) : Specified torque
 Non-reusable part
40 (408, 30)
40 (408, 30)
Ring
Fuel Tank Filler Pipe x 83.5 (35, 31 in.´lbf)
Fuel Tank Vent
Tube Set Plate
Fuel pump and
Sender Gauge
Assembly
Fuel Tank
Parking Brake CableCutoff
Valve
CoverEVAP Tube
Fuel Main Tube
Fuel Return Tube
Bracket
 Gasket
20 (204, 15)
- SFIFUEL TANK AND LINE
SF-29
1728 Author
: Date
:
2004 LAND CRUISER (RM1071U)
FUEL TANK AND LINE
COMPONENTS
CAUTION:

Always use new gaskets when replacing the fuel tank or component parts.

Apply the proper torque to all tightening parts.

SF0P0-12
BO0919
Crack Leakage
Deformation
FU0041
Pipe
Clip 2 - 7 mm (0.08 - 0.28 in.)
0 - 3 mm (0 - 0.12 in.)
Hose
B05015
Clamp
0 - 3 mm
(0 - 0.12 in.)
Area
Fuel Inlet Hose
SF-30
- SFIFUEL TANK AND LINE
1729 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSPECTION
INSPECT FUEL TANK AND LINE
(a) Check the fuel lines from cracks or leakage, and all con-
nections for deformation.
(b) Check the fuel tank vapor vent system hoses and all con-
nections for looseness, sharp bends or damage.
(c) Check the fuel tank for deformation, cracks, fuel leakage
or tank band looseness.
(d) Check the filler neck for damage or fuel leakage.
(e) Hose and pipe connections are as shown in the illustra-
tion.
If a problem is found, repair or replace the parts as necessary.

SF0XW-05
B06489
No.1 Rear Seat
Rear Seat Lock Cover
Front Floor CarpetLeg Cover
Rear Floor Carpet
Rear Floor Service
Hole Cover
Rear Door Scuff Plate
Step Plate
N´m (kgf´cm, ft´lbf) : Specified torque
41 (420, 30)
SF-10
- SFIFUEL PUMP
1709 Author
: Date
:
2004 LAND CRUISER (RM1071U)
COMPONENTS

B16438
Fuel Main Tube
Tube Joint Clip
Fuel Pump & Sender Gauge
Connector
Fuel Tank Vent Tube Set Plate
Fuel Pump and Sender
Gauge Assembly

Gasket
Tube Joint Clip
N´m (kgf´cm, ft´lbf) : Specified torque

Non-reusable part
3.5 (35, 31 in.´lbf)
Vapor Pressure Sensor & Connector
Fuel Return Tube
x 8
Tube Joint Clip
Tube Joint Clip
- SFIFUEL PUMP
SF-1 1
1710 Author
: Date
:
2004 LAND CRUISER (RM1071U)

B16439
Fuel Pump Filter

Clip
Rubber CushionFuel Suction Plate
with Sender Gauge
Lead Wire
Fuel Hose
Fuel Pump

Non-reusable part SF-12
- SFIFUEL PUMP
1711 Author
: Date
:
2004 LAND CRUISER (RM1071U)

B04997
Push
SF0XY-04
B16442
B16443
Insert Insert Insert
B16444
Clip
Clip
- SFIFUEL PUMP
SF-15
1714 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSTALLATION
1. INSTALL FUEL PUMP FILTER TO FUEL PUMP
Install the pump filter with a new clip.
2. INSTALL FUEL PUMP TO FUEL PUMP BRACKET
(a) Install the rubber cushion to the fuel pump.
(b) Connect the fuel hose to the outlet port of the fuel pump.
(c) Install the fuel pump by pushing the lower side of the fuel
pump.
3. INSTALL LEAD WIRE TO FUEL PUMP
4. INSTALL FUEL PUMP AND SENDER GAUGE AS-
SEMBLY TO FUEL TANK
(a) Install a new gasket to the fuel suction plate.
(b) Insert the fuel pump and the sender gauge assembly into
the fuel tank.
(c) Install the fuel tank vent tube set plate with the 8 bolts.
Torque: 3.5 N´m (35 kgf´cm, 31 in.´lbf)
5. CONNECT FUEL MAIN TUBE AND RETURN TUBE
(FUEL TUBE CONNECTORS) TO FUEL SUCTION
PLATE
(a) Before installing the tube connectors, check foreign mat-
ters on the connection between the nylon tube and the
suction plate.
(b) Attach the fuel tube connectors to the ports of the fuel suc-
tion plate and insert the clips until you hear a click.
(c) After the connection, pull out the clips to check to see that
they are installed securely.
6. CONNECT FUEL PUMP & SENDER GAUGE CONNEC-
TOR
7. CHECK FOR FUEL LEAKS (See page SF-1)
8. INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Install the rear service hole cover with the 2 screws.
(b) Cover the rear and front floor carpets.
9. INSTALL REAR DOOR SCUFF PLATES, STEP
PLATES AND REAR SEAT LOCK COVERS
10. INSTALL NO.1 REAR SEATS

A07061
TOYOTA
Hand-Held
Tester
DLC3SF10V-02
B04440
Up
Pulsation
Damper
Screw
B04441
SST
(Gauge)SST
(Adaptor)
SST
(Union)
Front Fuel Pipe
Gasket
- SFIFUEL PUMP
SF-7
1706 Author
: Date
:
2004 LAND CRUISER (RM1071U)
FUEL PUMP
ON-VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION
(a) Connect a TOYOTA hand-held tester or OBD II scan tool
to the DLC3.
(b) Turn the ignition switch ON, and press the TOYOTA
hand-held tester or OBD II scan tool main switch ON.
NOTICE:
Do not start the engine.
(c) Select the ACTIVE TEST mode on the TOYOTA hand-
held tester or OBD II scan tool.
(d) Please refer to the TOYOTA hand-held tester or OBD II
scan tool operator's manual for further details.
(e) If you have no TOYOTA hand-held tester or OBD II scan
tool, connect the positive (+) and negative (-) leads from
the battery to the fuel pump connector. (See step 3)
(f) Disconnect the fuel return hose from the clamp on the V-
bank cover.
(g) Remove the 2 bolts, nuts and V-bank cover.
(h) Check that the pulsation damper screw pop up when the
fuel pump operates.
If operation is not as specified, check following parts:

Fusible link

Fuses

EFI main relay

Fuel pump

ECM

Wiring connections
(i) Turn the ignition switch OFF.
(j) Disconnect the TOYOTA hand-held tester or OBD II scan
tool from the DLC3.
2. CHECK FUEL PRESSURE
(a) Check the battery positive voltage is above 12 V.
(b) Disconnect the negative (-) terminal cable from the bat-
tery.
(c) Remove the front fuel pipe from the LH delivery pipe (See
page SF-22).
(d) Install the front fuel pipe and SST (pressure gauge) to the
delivery pipe with the 3 lower gaskets and SST (adaptor).
SST 09268-45014 (09268-41190, 90405-06167)
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(e) Wipe off any splattered gasoline.
(f) Reconnect the negative (-) terminal cable to the battery.
(g) Connect a TOYOTA hand-held tester or OBD II scan tool
to the DLC3 (See (a) to (e) in step 1 on the check fuel
pump operation).
(h) Measure the fuel pressure.

B16435
Ohmmeter
5
4
SF-8
- SFIFUEL PUMP
1707 Author
: Date
:
2004 LAND CRUISER (RM1071U)
Fuel pressure:
265 - 304 kPa (2.7 - 3.1 kgf/cm
2, 38 - 44 psi)
If pressure is higher than the specification, replace the fuel
pressure regulator.
If pressure is lower than the specification, check these parts:

Fuel hoses and connections

Fuel pump

Fuel filter

Fuel pressure regulator
(i) Disconnect the TOYOTA hand- held tester from the
DLC3.
(j) Start the engine.
(k) Measure the fuel pressure at idle.
Fuel pressure:
265 - 304 kPa (2.7 - 3.1 kgf/cm
2, 38 - 44 psi)
(l) Stop the engine.
(m) Check that the fuel pressure remains in the specification
below for 5 minutes after the engine stop.
Fuel pressure:
147 kPa (1.5 kgf/cm
2, 21 psi) or more
If the pressure is not as specified, check the fuel pump, pres-
sure regulator and/or the injectors.
(n) After checking the fuel pressure, disconnect the negative
(-) terminal cable from the battery and carefully remove
the SST to prevent gasoline from splashing.
SST 09268-45014
(o) Reinstall the front fuel pipe to the LH delivery pipe (See
page SF-27).
(p) Reconnect the negative (-) terminal cable to the battery.
(q) Check for fuel leaks (See page SF-1).
(r) Reinstall the V-bank cover with the 2 bolts and nuts.
(s) Reconnect the fuel return hose to the clamp on the V-
bank cover.
3. INSPECT FUEL PUMP
(a) Remove the No.1 rear seats.
(b) Remove the 2 rear door scuff plates, the step plates and
the rear seat lock covers.
(c) Pull off the front and rear floor carpets.
(d) Remove the 2 screws and the rear floor service hole cov-
er.
(e) Disconnect the fuel pump & sender gauge connector.
(f) Using an ohmmeter, measure the resistance between ter-
minal 4 and 5.

B16436
Battery
4 5
- SFIFUEL PUMP
SF-9
1708 Author
: Date
:
2004 LAND CRUISER (RM1071U)
Resistance: 0.2 - 3.0 W at 20°C (68°F)
If the resistance is not as specified, replace the fuel pump and/
or the lead wire.
(g) Inspect the fuel pump operation.
Connect the battery positive (+) lead to terminal 4 of the
connector, and the battery negative (-) lead to terminal 5.
Check that the fuel pump operates.
NOTICE:

These tests must be done quickly (within 10 seconds)
to prevent the coil burning out.

Keep the fuel pump as far away from the battery as
possible.

Always change the connection on the battery side.
If operation is not as specified, replace the fuel pump and/or
lead wire.
(h) Reconnect the fuel pump & sender gauge connector.
(i) Reinstall the rear floor service hole cover with the 2
screws.
(j) Reinstall the front and rear floor carpets.
(k) Remove the 2 rear door scuff plates, the step plates and
the rear sear lock covers.
(l) Reinstall the No.1 rear seats.

SF0XX-04
B16440
Pull
Enlarge
Tube Joint
Clip
B16441
Plug
Turn
Turn
- SFIFUEL PUMP
SF-13
1712 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REMOVAL
CAUTION:
Do not smoke or work near an open frame when working
the fuel pump.
1. REMOVE NO.1 REAR SEATS
2. REMOVE REAR DOOR SCUFF PLATES, STEP
PLATES AND REAR SEAT LOCK COVERS
3. REMOVE REAR FLOOR SERVICE HOLE COVER
(a) Take off the front and rear floor carpets.
(b) Remove the 2 screws and rear floor service hole cover.
4. DISCONNECT FUEL PUMP & SENDER GAUGE CON-
NECTOR
5. DISCONNECT FUEL MAIN TUBE AND RETURN TUBE
(FUEL TUBE CONNECTORS) FROM FUEL SUCTION
PLATE
CAUTION:

Perform disconnecting operation of the fuel tube con-
nector (quick type) after reading the precautions.
(See page SF-1)

Prevent the retained pressure in the fuel line from
splashing inside the vehicle compartment.

Be careful not to damage the contact surface or let the
foreign matters on there when sealing the tube and
the suction plates with the quick connectors through
O-ring.

Be sure to perform the disconnection by hand. Do not
use tools.

Do not bend or turn the nylon tube by force.
(a) Before the operation, remove foreign matters or dirt stick-
ing to the tube joint clips.
(b) Enlarge the tip of the clips with fingers and pull them out
for disconnection.
(c) Pull out the fuel main tube and the return tube.
If the nylon tube and the suction plate stick together, ease the
connection by turning the nylon tube with fingers and pull it out
for disconnection.
NOTICE:
Plug the port of the fuel suction plate with a clean rubber
cap.
(d) After the disconnection, protect the connector with a plas-
tic bag.