Fuel Sock Replacement in a 97 Land Cruiser

[DirtaddictLC80]

First off I want to give credit to CruiserJack, who put together a really detailed description (with great pics) of how to replace the fuel sock in our 80 series land cruiser. The thread can be found here:
https://forum.ih8mud.com/80-series-tech/374853-fuel-sock-replacement-pictures.html

With my rig approaching 180K, and with most of my other PMs done, I thought I would spend a few hours of my afternoon to get this out of the way. I had been sitting on the parts for several months and wanted to get them out of my garage and onto the truck.

I followed the directions pretty closely although I had to do a few things differently. First off, the fuel sock for the 97 is different than for a 91. The fuel sock part number is:

23217-16490: 8/1992-1/1998

This is what I got when I ordered from CDan, and is cross referenced in this thread:
https://forum.ih8mud.com/80-series-tech/384394-fuel-sock-part-number-early-fzj80-93-a.html

In addition, I had an issue fitting the new fuel sock onto the fuel pump. I had the same problem as Spartan, as mentioned in this thread:
https://forum.ih8mud.com/80-series-tech/465782-rth-please-fuel-sock-1997-a.html

Unfortunately, the thread closed with no one documenting a fix. Luckily, I was able to find a quick fix to this, although it did take me awhile to think of it.

Also worth noting are torque values. These weren't documented in CruiserJack's thread, but are in the FSM. For those who don't have it, I've included the pertinent torque specs below.

- REMOVE SECOND (ROW) SEATS: Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
- Remove the union bolt and gaskets, and disconnect the outlet pipe from the pump bracket: Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
- REMOVE FUEL PUMP BRACKET ASSEMBLY FROM FUEL TANK. (a) Remove the 8 bolts: Torque: 3.9 N·m (40 kgf·cm, 35 in.·lbf)


Now, on to my documentation and pics!

 

[DirtaddictLC80]

Fuel Pump/Sock Removal

Removal of the fuel pump and sock was pretty straight forward. Like others, my cover was very dusty so I vacuumed and blew out as much dust/dirt as I could. I then wiped as much as I could away before proceeding with removing the cover. Here's a few pics of what I found:


Fuel Pump/Sock Head Unit


Old Fuel Sock


Old Fuel Pump Gasket


Old Fuel Pump Gasket


Old Fuel Sock

The sock, for the most part, was in good shape, although there was a fair bit of dirt captured in front of where the fuel passes into the pump from the fuel sock. Definitely had a lot more life in it, but what the heck, right?

The gasket has definitely seen better days, but again, it was probably sealing fine. Still, I felt better replacing it.

 

[DirtaddictLC80]

New Fuel Sock Replacement

As I mentioned in my intro, I had a bit of a problem at first, getting the new fuel sock to fit on the pump. But first things first. I gently pulled the fuel pump, with the fuel sock still attached, away from the bracket. Then I removed the rubber gasket to expose the clip holding the old fuel sock in place.


Rubber Cap That Fits Over Fuel Sock


Removing Old Fuel Sock

 

[DirtaddictLC80]

Gently Reaming the Opening of the New Fuel Sock

Here's where I hit a speed bump. The new fuel sock would not fit on the inlet of the pump. For some reason, it was just a little too small. This is where I got the idea to gently stretch the hole of the fuel sock by reaming it with a 10mm Allen Wrench.

I tapped the Allen Wrench into the fuel sock, and then twisted a bit back and forth. The plastic wall of the opening was not damaged, but must have stretched enough because I was able to push the fuel sock all the way into the pump. It was a very tight fit. A new metal clip (bought when I picked up the new fuel sock) then went on to keep everything in place.


Fuel Sock Opening Reamed with 10mm Allen Wrench (Note the old fuel sock is seen in this photograph. It was used for demonstration purposes only)


New Fuel Sock Attached to Fuel Pump (note, metal clip is not attached in this pic)


Once everything was attached to the pump, I gently put the pump back in the tank and snugged everything up.

All in all, it took my longer than expected, but that was due to me taking my time to keep everything clean, and dealing with the fitment issue on the new fuel sock.

Hope this helped!

 

[VonCannon]

I just did this myself. If your 8 phillips head screws are rusted like mine were, you can use a 8mm socket to take care of them.

 

[DirtaddictLC80]

:whoops:

Just realized that I forgot to replace the banjo bolt crush washers. Those are non-reusable. I'll be getting those in shortly. At least it will be a quick swap since I only have to remove the top cover.

 

[spartan]

Here's where I hit a speed bump. The new fuel sock would not fit on the inlet of the pump. For some reason, it was just a little too small. This is where I got the idea to gently stretch the hole of the fuel sock by reaming it with a 10mm Allen Wrench.

I tapped the Allen Wrench into the fuel sock, and then twisted a bit back and forth. The plastic wall of the opening was not damaged, but must have stretched enough because I was able to push the fuel sock all the way into the pump. It was a very tight fit. A new metal clip (bought when I picked up the new fuel sock) then went on to keep everything in place.


Fuel Sock Opening Reamed with 10mm Allen Wrench (Note the old fuel sock is seen in this photograph. It was used for demonstration purposes only)


New Fuel Sock Attached to Fuel Pump (note, metal clip is not attached in this pic)


Once everything was attached to the pump, I gently put the pump back in the tank and snugged everything up.

All in all, it took my longer than expected, but that was due to me taking my time to keep everything clean, and dealing with the fitment issue on the new fuel sock.

Hope this helped!

Thank you for sharing. Smarter than me. After several board " experts " telling me I was full of it; that they had never heard of the issue, I gave up and put the old one back on. Got PO'ed and threw the new one away. Guess I shoulda thought a little more. Now I don't feel like such a dumb butt. I don't think I would have done or do a redo anyway. The old sock was clean as could be and I got all the new seals and parts in.

 

[carterjkendall]

Part number for those crush washers on the baja bolts? Or specs?

 

[Kernal]

@carterjkendall : IMHO it helps to learn how to find part numbers yourself ie: no AI here, use your own I.

One method, go to: partsouq dot com , type in your VIN, then search for the part, assembly, or system you're interested in.

Example: search for Fuel pump and you should find a diagram like below, then look for the part you need,
in this case a copper "gasket", you'll need two (2). Tip: order extras if you're prone to dropping small parts that can get lost easily.

You'll have to go to that website yourself as some of the part numbers seem to be missing from the diagram below

 

[carterjkendall]

@carterjkendall : IMHO it helps to learn how to find part numbers yourself ie: no AI here, use your own I.

One method, go to: partsouq dot com , type in your VIN, then search for the part, assembly, or system you're interested in.

Example: search for Fuel pump and you should find a diagram like below, then look for the part you need,
in this case a copper "gasket", you'll need two (2). Tip: order extras if you're prone to dropping small parts that can get lost easily.

You'll have to go to that website yourself as some of the part numbers seem to be missing from the diagram below

View attachment 3899908

Cool thanks.

 

[carterjkendall]

@carterjkendall : IMHO it helps to learn how to find part numbers yourself ie: no AI here, use your own I.

One method, go to: partsouq dot com , type in your VIN, then search for the part, assembly, or system you're interested in.

Example: search for Fuel pump and you should find a diagram like below, then look for the part you need,
in this case a copper "gasket", you'll need two (2). Tip: order extras if you're prone to dropping small parts that can get lost easily.

You'll have to go to that website yourself as some of the part numbers seem to be missing from the diagram below

View attachment 3899908

The reason I asked is cuz there are no part numbers for the crush washers on that schematic for each side of the banjo bolt. I’m not a full idiot just reaching out for help to someone who already did the leg work to find the part numbers that seem to not be listed in the normal searching methods lol.

 

[Kernal]

@carterjkendall : did you go to Partsouq dot com and type in your VIN?

If you don't want to type in your VIN, you can click on:
Toyota symbol top left on the first page
Scroll down to Land
Click on 80 Series
Then scroll down to the Model you have (in the US it should be FZJ80L-GNPEKA)
(it's printed on the VIN Sticker on the driver's door below the latch)

Either way you get there you will see three tabs, Categories, Search, Groups,

If you choose Categories you have to scroll down until you find Fuel Injection System
but there are two sections, look for the Fuel Pump Bracket diagram.

I find it's a bit quicker to start at Search then type in what you're looking for, in this example: Fuel Pump (or Fuel Injection)

Or you can click on the Groups tab then scroll down to Fuel System, then look for the fuel pump bracket and fuel pump diagram:

There are other websites that may show the part you need, Toyotapartsdeal for example often shows some of the smaller parts but IME Partsouq shows every part down to the smallest screw.

 

[carterjkendall]

@carterjkendall : did you go to Partsouq dot com and type in your VIN.

You'll see three tabs, Categories, Search, Groups,

Search for Fuel Pump (or Fuel Injection)







There are other websites that may show that part, Toyotapartsdeal for example often shows some of the smaller parts but IME Partsouq shows every part down to the smallest screw.

View attachment 3900391

View attachment 3900393

yes notice there are no part numbers next to the crush washers hence why I asked the OP if he had the part numbers since he said in this thread that he purchased new crush washers.

 

[Kernal]

@carterjkendall : the OP has not been on the forum for a couple of years. Maybe check again by going to the Partsouq website as detailed above, pretty sure you'll find the numbers you need.

 

[carterjkendall]

@carterjkendall : the OP has not been on the forum for a couple of years. Maybe check again by going to the Partsouq website as detailed above, pretty sure you'll find the numbers you need.

The part numbers are not on partsouq, thank you.

 

[Kernal]

Ok, so I just went to Partsouq.

Go online to Partsouq . com
Type in the VIN of your vehicle (found on the sticker located on the driver's door below the latch)
Search for Fuel Pump or Fuel Injection System in this case and you'll see the first image below
(VIN number partially obscured in this example but you should type the complete VIN)

Click on the parts diagram on the left above:

Click on the part you want, in this case 90430-12026:

You can order 90430-12026 (metal gaskets) from any Toyota dealer or other online sources