1976 FJ40 Adding Fuel Line Return H3662 Aftermarket Carb?

Ackcruisers

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I’m replacing the fuel system on my 4/1976 South American 40 from tank all the way to carb. While investigating the benefits of the fuel return, I’ve decided to add one.

I’m making all 5/16 fuel lines. In looking at my aftermarket h3662 carb, (replica of 21100-61012) It appears there is a bolt blocking fuel return ( see image #1) . What’s strange about the H3662, all I’ve seen online do not have fuel return line at the carb. Has anyone seen an h3662 with fuel return banjo bolt similar to image #2 below? Anyone know where I can buy one?

#1
4227C29F-6945-45DB-8155-954A69D68C29.jpeg


#2
4F19E9DC-F6EE-406F-AB86-2D76193BFFCC.jpeg


NOTE re: fuel return. (from Fj40jim)

There is a return system. It consists of a banjo bolt and a banjo fitting. The banjo bolt contains a brass restrictor (jet), and behind that is a rubber check valve/pressure regulator. The restrictor limits maximum fuel return flow. The rubber check valve has a cracking pressure, to maintain a minimum pressure in the fuel inlet of the carb.
The banjo bolt is 12x1.25 with crushwashers, the banjo fitting is 13x1.5 compression.
 
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why not make it similar to a later year 40?
use a later fuel pump and have the return go from the pump back to the tank. seems to work just fine on all 1979+ 40's and 60 series.


Only thing I would add to this simple fix is be sure and to see if the pump you switch to requires an insulator between the block and the pump. Those the arm is different and will be too close to the cam without the insulator.
 

ToyotaMatt

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the whole RETURN LINE topic here is a USA Spec. Safety and SMOG requirement TECH.

California started and well 49 states FEDERAL emissions and 50 states legal safety requirements followed soon after ....


----------------------------------------------------------------------------------------------------------------------------------


WHY does anyone want to install a new aftermarket return line CHINA Made Carburetor replacement in the first place any way ?



LET's openly discuss this TECH topic , im intrigued at what the various reasons may be ?

-
i have indeed Modified a CHINA MADE AFTERMARKET NEW 2F UNIT with a OEM fuel return fitting , i have the tech photos and will share the step by steps


but , let first hear everyone's 411 on the WHY's from all who care to share


thanks






DSCN0683.JPG


 

3_puppies

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Only thing I would add to this simple fix is be sure and to see if the pump you switch to requires an insulator between the block and the pump. Those the arm is different and will be too close to the cam without the insulator.


easy way to figure if it needs a spacer on the fuel pump
3 lines at the pump needs a spacer, 79 and newer in stock form
2 lines at the pump no spacer needed, 78 and older in stock form
 

Ackcruisers

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Adding a 7/79+ fuel pump with fuel return line makes the most sense to me. I guess the pressure is relieved at the pump returning the fuel to tank. Toyota engineers must have thought this was better.

It looks like this is the one to order and still available from Toyota 23100-61050.

See diagrams below that show spacer for 1979 fuel pump with 3 lines vs the 2 line pump. Thanks @3_puppies, so no spacer required when installing the 1979 fuel pump on a pre 7/79 that came with the two line pump. Just the single gasket.

5FBB5315-4056-4A8E-A01A-F20832D68A4F.jpeg

F3894A4B-0347-4EE5-9C84-B502E45F06CD.jpeg
 

Ackcruisers

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the whole RETURN LINE topic here is a USA Spec. Safety and SMOG requirement TECH.

California started and well 49 states FEDERAL emissions and 50 states legal safety requirements followed soon after ....


----------------------------------------------------------------------------------------------------------------------------------


WHY does anyone want to install a new aftermarket return line CHINA Made Carburetor replacement in the first place any way ?



LET's openly discuss this TECH topic , im intrigued at what the various reasons may be ?

-
i have indeed Modified a CHINA MADE AFTERMARKET NEW 2F UNIT with a OEM fuel return fitting , i have the tech photos and will share the step by steps


but , let first hear everyone's 411 on the WHY's from all who care to share


thanks





There is a lot covered on mud about fuel line return benefits. It would be great to see how you added the return line on H3662 carbs.
 

3_puppies

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Adding a 7/79+ fuel pump with fuel return line makes the most sense to me. I guess the pressure is relieved at the pump returning the fuel to tank. Toyota engineers must have thought this was better.

It looks like this is the one to order and still available from Toyota 23100-61050.

See diagrams below that show spacer for 1979 fuel pump with 3 lines vs the 2 line pump. Thanks @3_puppies, so no spacer required when installing the 1979 fuel pump on a pre 7/79 that came with the two line pump. Just the single gasket.

View attachment 2896485
View attachment 2896486


don't get confused by the years
any pump can be used on any block even the 3F block as they were carbed in other countries

the main thing to remember is 3 lines uses a spacer and 2 lines does not
the arm is longer on the 3 line pump thus requiring the spacer
 

Ackcruisers

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Thanks for clarifying. So for the 3 line fuel pump you will need:

Qty: (1) 90923-06009 spacer
Qty: (2) 90923-05019 gasket
 
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ToyotaMatt

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Thanks for the clarifying. So for the 3 line fuel pump you will need:

Qty: (1) 90923-06009 spacer
Qty: (2) 90923-05019 gasket


NO !

Paul , this is not correct and will cost you , my dear Friend and Solid Mud Buddy too / anyone MORE $ in the end game , and consume MORE Valuable and expensive FIPG ,

parts # 00295-00102 / 00295-00103



Instead ORDER : qty x 1
#90923-06010


ONLY order from YOUR LOCAL TOYOTA Dealership Parts Dept. / NOT TOYOTA PARTSTEAL either to be frank here ,

( they will Scam and RIP you off in shipping in the end ) sorry to sound harsh but they SU#K ! :mad:




90923-06010.jpg
 
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Ackcruisers

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NO !

Paul , this is not correct and will cost you , my dear Friend and Solid Mud Buddy too / anyone MORE $ in the end game , and consume MORE Valuable and expensive FIPG ,

parts # 00295-00102 / 00295-00103



Instead ORDER : qty x 1


ONLY order from YOUR LOCAL TOYOTA Dealership Parts Dept. / NOT TOYOTA PARTSTEAL either to be frank here ,


( they will Scam and RIP you off in shipping in the end ) sorry to sound harsh but they SU#K ! :mad:
Appreciate the guidance, Matt. However, the pump mechanical arm needs to be “shortened“ .

The schematic calls for a spacer, and two gaskets.

The part numbers are as follows: (links are provided to TPD only for verification of part availability).

Spacer/90923-06001 link to TPD
Gasket/90923-05019 link to TPD

CityRacer has a great price on the pump with gaskets and spacer.

DC6EA3A4-AE68-4FF6-8A63-46C4A81390FB.jpeg


I like FIPG but will use gasket and spacer in this application.
 
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ToyotaMatt

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Appreciate the guidance, Matt. However, the pump mechanical arm needs to be “shortened“ .

The schematic calls for a spacer, and two gaskets.

The part numbers are as follows: (links are provided to TPD only for verification of part availability).

Spacer/90923-06001 link to TPD
Gasket/90923-05019 link to TPD

CityRacer has a great price on the pump with gaskets and spacer.

View attachment 2897578

I like FIPG but will use gasket and spacer in this application.






i am aware the later return style pump requires a spacer , and 2 gaskets ,

- you should shop around a bit more for a better price on the correct factory fuel pump kit perhaps ? :)

- FIPG on the Correct vulcanized gaskets spacer 1 piece combo is required 100% or u WILL have a leak ....

- i don't know of another vendor whom also includes new gold cad plated oem mounting hardware too ?

-







90923-06010 - Copy.jpg




1642513261804.png



1642513332803.png





1642513381653.png
 
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Ackcruisers

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That's a deal, Matt.

Wasn't aware you VintageTeq stocked the fuel pump “kit” including bolts and your added value tech support.

I just ordered the 90923-06010. Having gasket attached to spacer is better in my view.

FIPG 00295-00103 is below for those reading this in the future.

B5B1128D-D6E0-4C5A-90D4-72D5DE5B375F.jpeg
 

Ackcruisers

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@ToyotaMatt the bolts that came off my old fuel pump appear to be shorter than required for the new pump. The new pump with return has the spacer. What‘s the factory bolt length for the NLA 90119-08132 bolts for this fuel pump. Are they m8x1.25 x 20mm length? I’m in the middle of my complete fuel system overhaul.

8B4F2E09-DD6E-405D-8D8A-0DC090F057A8.jpeg


25A15CB0-C27A-4342-AA0E-772529790F6F.jpeg
 

ToyotaMatt

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@ToyotaMatt the bolts that came off my old fuel pump appear to be shorter than required for the new pump. The new pump with return has the spacer. What‘s the factory bolt length for the NLA 90119-08132 bolts for this fuel pump. Are they m8x1.25 x 20mm length? I’m in the middle of my complete fuel system overhaul.

View attachment 3009715

View attachment 3009716



did i send you a pump kit paul ?

or .............


if i did send you a oem pump kit , i always include 2 oem non -usa SEMS double washers bolts

YES , early non spacer pumps say a 1976 are different lengths then the later spacer required return line circuit pump



im a bit confused since you have a 76 but mention the retune line later pump above ?

i carry both verities in stock at all times

i can ship u out a set tomorrow of both lengths if your unsure ?

hit me back or call or text shop hot line or reply back here as i watch this thread with great fascination 24/7

thanks matt



221004998454_01425 - Copy - Copy1.jpg
 

Ackcruisers

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Thanks. Matt. I purchased a late model fuel pump as the return is located on pump vs. carb. I just need to know the factory length of these bolts...The factory fuel pump bolts are here.
 

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