OEM Subtank Retrofit/Install Project With Pics

S.CarolinaFZJ80 · 08-17-09, 12:05 AM

Is this the complete bracket for the sub tank transfer pump?

JPHockerAZ · 08-17-09, 09:10 AM

Quote:

Originally Posted by S.CarolinaFZJ80

Is this the complete bracket for the sub tank transfer pump?

Yes, that should work.

jp importz · 08-26-09, 09:39 PM

I wanted to say many thanks, shout out to JIM!!! Without him this project is almost impossible. After 4 months the project is almost done. The only thing we have to do is wire up the compass. We bought everything new from Japan :( bad move ....... I will take some pictures after she is clean up.
JP

Clint79 · 08-27-09, 08:52 AM

A Mate who is a lpg/propane fitter, when fitting the tank LPG tanks to 80 series 100 and 105 series the sub tank has to be removed he has pile of sub tanks with fuel pumps for sale no fillers, i mentioned this in the 100 series section thread of sub tanks somewere if anyone is interested PM me and we can work out priceing etc

jp importz · 09-03-09, 08:17 AM

Anyone had any luck with the compass install, Please let me know. We had a wire harness from the compass to the display unit and it still doesn't work. jpimportz@yahoo.com. Any folks in here from Australia? Thank you in advance.
JP

mot · 09-03-09, 08:28 AM

Not to sound dumb, but do you have the magnetic field sensor that is mounted inside?

I believe it needs to be mounted on a magnetically-shielded bracket or something crazy like that! (The last I checked with Toyota it was already discontinued).

jp importz · 09-03-09, 08:49 AM

Someone mention about the bracket and such. To my knowledge the customer didn't have any of that. Just sensor and the plastic cover. Maybe there is more to it then just plug it in? I've search for documents but didn't turn up with anything. Thanks
JP

mot · 09-03-09, 09:12 AM

cruiserdan has done the retrofit on his FZJ and said that it was pain in the butt to get it installed and would not do it again.

G'luck!

jp importz · 09-03-09, 10:29 AM

Tell me about it. Everything is done on this truck .. Except the compass. Do you have Dan's contact? Thank you
JP

mot · 09-03-09, 03:27 PM

Just look up "cruiserdan" here on Mud.

He's "THE MAN" when it comes to LC parts guy.
He's a vendor here and he is with American Toyota in NM.

There "might" be someone else who has done the mod, as I've seen someone offering the overhead console with the senseor mounting bracket a couple of years ago. Another possibility might be to get a used one from a junk yard/wrecker...

Good luck!!

keithf · 09-05-09, 08:18 PM

Nice work on the install Jim - you really went all out by going OEM for everything!

FYI to any-one in the US - I have an OEM 13gal petrol subtank FOR SALE - see sig.

Thanks! Keith.

jp importz · 10-15-09, 05:56 PM

WE made a video for this subtank installation. The only thing that doesn't work is the compass. We are waiting for the gentlemen from Aussie to come from the military. He is going to take apart his truck apart to compare wiring with us. Thank you Jim all of the help.
Regards
http://www.facebook.com/v/167864334592

S.CarolinaFZJ80 · 10-19-09, 05:12 PM

I just came home to two boxes from Australia sitting on my doorstep. That's right my factory subtank set-up has arrived.

If any of you here in the US or Canada have a Fuel Transfer ECU laying around... let me know.

Here are the pics.

S.CarolinaFZJ80 · 10-19-09, 05:14 PM

Here are some more pictures of the components.

S.CarolinaFZJ80 · 10-19-09, 05:16 PM

... and some more pics.

S.CarolinaFZJ80 · 10-19-09, 05:18 PM

... still more

S.CarolinaFZJ80 · 10-19-09, 05:25 PM

And now for the switch and wiring. I got the stock wiring from the Oz harness with the plug for the switch. However, he already sold the switch so I got this one from someone else. Notice the harness has 6 terminals and the switch has 7.

I hope I have the correct switch or can just add a terminal to the harness. I was told that this switch came from a gasser.

S.CarolinaFZJ80 · 11-10-09, 09:33 PM

Where did you guys get your rivnuts for the sub tank mounting straps?

Do you have any pics of the rivnut install and the holes that you drilled in the floor?

elmariachi · 11-11-09, 07:51 AM

Quote:

Originally Posted by S.CarolinaFZJ80

Where did you guys get your rivnuts for the sub tank mounting straps? Do you have any pics of the rivnut install and the holes that you drilled in the floor?

CDan gave me mine from the last of his personal stock, but you can get them here:

McMaster-Carr

You want the "Open End Knurled Rivet Nuts." I don't recall what size, but I think the bolt heads on mine were 14mm.

FYI there is also a trick to installing these things that involves two wrenches and a bolt to collapse the nut while its in the mounting hole. Search around and you should find this on the web, example:Metal skid plate installation VW

Otherwise you will have to buy the tool. Also, the body ribs where these are mounted are very thin like the floorpan so you only get one good shot, so make it count.

S.CarolinaFZJ80 · 11-12-09, 10:45 AM

Thanks elmariachi. Do you happen to have any photos of the cargo floor after you put the rivnuts in?

Also, has anyone used carriage bolts with the nuts on the underside of the body to mount their tank or welded nuts to the interior of the cargo area?

Just exploring options.

elmariachi · 11-12-09, 11:40 AM

Quote:

Originally Posted by S.CarolinaFZJ80

Thanks elmariachi. Do you happen to have any photos of the cargo floor after you put the rivnuts in?Just exploring options.

Sam, you might want to crawl under the truck and look around. The rivnuts don't go into the floor, they go into two longitudinal u-channel ribs stake-welded up against the floorpan.

Here are some good pics and commentary from George Scalero:

Auxiliary tank

Its not the most robust arrangement, so anyone who can engineer a better mousetrap, it might be worth it.

Jim

JPHockerAZ · 11-12-09, 02:03 PM

On a side note the rivnuts I used were slightly (Not by much at all) longer than the ones every one else seems to use. I had a hell of a time getting the Rivnuts to collapse in to place using the bolt/washer/nut/washer/nut method. I found it easier to use about 8 slightly oversized regular washers on a bolt and just torque it down. The rivnut collapsed in seconds.

S.CarolinaFZJ80 · 11-12-09, 02:09 PM

Thanks for that thread Jim. Unfortunately, my truck is in the shop getting a new head but I will look at it when I get it back tomorrow. Those links answered my question about the holes for the subtank straps but created more ?'s about the correct size rivnuts & the holes for the fuel transfer assembly bracket.

(See pic borrowed from this thread Auxiliary tank)

Did you do this on your install? If so, did you put the bolt heads on the interior floor & the nut on the bottom side?

S.CarolinaFZJ80 · 11-12-09, 02:16 PM

The pic refered to in my previous post wouldn't post. It said it was invalid. Anyway, it was the one about half way down the link (Auxiliary tank) with the text "5 mounting holes drilled into floor"

S.CarolinaFZJ80 · 11-12-09, 02:22 PM

Quote:

Originally Posted by JPHockerAZ

On a side note the rivnuts I used were slightly (Not by much at all) longer than the ones every one else seems to use. I had a hell of a time getting the Rivnuts to collapse in to place using the bolt/washer/nut/washer/nut method. I found it easier to use about 8 slightly oversized regular washers on a bolt and just torque it down. The rivnut collapsed in seconds.

Any idea on what size "everyone else is using"?

JPHockerAZ · 11-12-09, 03:21 PM

Quote:

Originally Posted by S.CarolinaFZJ80

Any idea on what size "everyone else is using"?

M8 x 12 thread and .495 Outside Diameter

"they" use a 17mm tall rivnut and IIRC I used 20mm.

S.CarolinaFZJ80 · 11-13-09, 12:17 PM

Thanks JP. There is no 12 thread listed as an option for an M8 on the link that Jim provided above to McMaster-Carr . Did you mean a 1.25 thread?

So based upon the pics in George's thread, are you guys using the Steel, Open-End Knurled Rivet Nuts that are Zinc Yellow Chromate Plated?

If so, these are the only two that they source in the M8, 1.25 thread. http://www.mcmaster.com/#rivet-nuts/=4hkxcr

Any idea what the combined thickness of the metal there is (see pic below)? There are two listed.

Rivet Material Thickness Range Part # Price
0.7 mm - 3.8 mm 95105A191 $4.89 per Pack of 10 http://www.mcmaster.com/#95105a191/=4hm8oq
3.8 mm - 7.9 mm 95105A195 $5.29 per Pack of 10 http://www.mcmaster.com/#95105a195/=4hm7o0

Here are a few pictures from their website just to confirm that these are exactly what is needed.

S.CarolinaFZJ80 · 11-13-09, 01:58 PM

.495 inches diameter works out to be 12.7mm yet the two options above are 13.46mm in sleeve diameter(A) and 17.4mm in lip diameter (C). And a drill size of 13.5mm.

S.CarolinaFZJ80 · 11-15-09, 01:42 AM

JP - I just confirmed that my sub tank strap bolts that came out of my donor '96 Australian 80 are M10 x 1.25 fine pitch with a 14mm head.