OEM Subtank Retrofit/Install Project With Pics

[S.CarolinaFZJ80]

Good work Steve! I have a similar issue with my system. I think that there is possibly some differences in wire colors my '96 & El Marichi's '97. This may account for the issue. I am actually tearing into mine tomorrow morning to try and sort out the wiring issue too.

I plan to jumper the transfer pump with hot 12v+ (fused of course) to see if the pump actually works, then back track all of my wiring. I think that I found several issues from my install notes and diagrams.

I'll post up my findings. Hopefully, 70sguy will be able to post up a PDF version of those wiring diagrams. That will really help out.

I hope that I can figure it all out on my day off.

As for the leak, I would think that the filler neck would have serviceable parts and gaskets to stop your leak. Hopefully that is the case.

BTW - I have new breather tube gaskets for the main tank if you want a couple. I had to buy them in a 10 pack.

 

[Snailtrail]

I can help out with a PDF version of the Aug '96~ diagram.

 

[S.CarolinaFZJ80]

I can help out with a PDF version of the Aug '96~ diagram.

Thanks Snailtrail. I actually mistakenly put down '95 & later in my post requesting the EWD's. I actually need one from a '92 to prior than Jan. '95 80 series Petrol, as this is the setup that uses and external Fuel Transfer ECU that us U.S. guys are using.

Would you happen to have one from those years. The one that 70sguy posted is great but I just can't read the small print on it since it is a photograph.

Also, I am wondering if the Southern Hemi 80's have a different electrical connector codes, as all of the diagrams I have seen show different connector codes (3 character alpha numeric codes in small boxes shown on diagram) than what is labeled in the US spec electrical wiring diagram. I wonder if the same connector up here is labeled differently down there.

Any chance you can post up some scans that identify what connectors are what. The US EWD book has them in the first several pages of the book.

BTW - that's a hilarious screen name!

 

[azTony]

I have a LRA 44 gallon aux tank I am thinking about getting rid of. I just pulled it from my rig today. I have all the mounting hardware.

 

[70sguy]

Also, I am wondering if the Southern Hemi 80's have a different electrical connector codes, as all of the diagrams I have seen show different connector codes (3 character alpha numeric codes in small boxes shown on diagram) than what is labeled in the US spec electrical wiring diagram. I wonder if the same connector up here is labeled differently down there.

Any chance you can post up some scans that identify what connectors are what. The US EWD book has them in the first several pages of the book.

BTW - that's a hilarious screen name!

Yes, the plug reference codes in the EWDs often differ but it doesn't necessarily mean a different plug.
Here is some plug dia pics from EWD 169F 92/08 to 95/01 Gen market 80 series. Taken on the page adjacent to the FZJ80 fuel transfer diagrams.

 

[S.CarolinaFZJ80]

Thanks 70sguy for those pictures that helps clarify some of what's what but the codes I was referring to are circled in red in the following wiring diagram.
Take for example the F37 Fuel Level Switch; this is the sub tank float switch. It has 3 wires a fuel level high (R-Y), a low level (Y-L)and a ground (W-B) and is a 3 pin plug but see the Bb1 in the Rectangle. This is what I am referring to.
F37 is the parts code, the number to the left of the rectangle in the wires location in the harness but what does the Bb1 refer to or Bd2, BO1, BL1 & BL3 for that matter? I thought it was the type of plug hence the similar 2 alpha, 1 number code that is similar the ID1 or ID2 listed in the US EWD manual.
Any ideas?

 

[70sguy]

The parts codes on the pics I sent (F25, F27 etc) are more like location reference codes, they are used on the "Position of parts in vehicle" pages. The plugs on those pics are all Harness to component plugs, I will attach the harness to harness plug pics PDQ which will jive with the BL3 type codes.

 

[S.CarolinaFZJ80]

Thanks 70sguy!

I have since found pictures of most the codes from my previous post EXCEPT for two; BL3 & Bd2. I did not happen to see these two in the US EWD manual.

 

[70sguy]

Here are the locations and diagrams for the Harness to harness plugs on the back end of the 80.

 

[S.CarolinaFZJ80]

Thanks! That just leaves 1 left, the BL3 connector.

 

[70sguy]

I think there is a typo in the EWD.
The only thing that makes sense is that BL1 and BL3 are actually
IL1 and IL3 (ID1 and ID3 in US EWD 166U)
Perhaps the elmariachi can shed some light on the plug detail in the kickpanel area for you.

The simple diesel set up is looking better all the time!

 

[S.CarolinaFZJ80]

Got it.

The AUS IL1 or BL1 = US ID2
AUS IL2 or BL2 = US ID1
AUS IL3 or BL3 = US ID3

 

[70sguy]

Something like that.. check with elmariachi to see what he knows maybe.
These EWDs are making my head hurt, I gota give this a rest.

 

[S.CarolinaFZJ80]

Thanks for posting those pics up. That helped out a ton.

 

[CycloSteve]

She's Alive!

Thanks 70's Guy for the diagrams...they definitely helped me to debug my setup pretty quickly.

Sam, the difference with the 97's and 96's is the two wires to check from the ECU to the ST Switch.

I had wired the P/G wire from the kick-panel to Pin 3 on the ST Switch when it should have been the P/Y wire. On the original diagram there are supposed to be two different P/B wires at pins at the ECU and kickpanel, where my rig had a P/G in Pin 4 and P/Y in Pin 5. My mistake luckily was a minor one with no side effects.

The system lights up green on pressing the button, and transfers perfectly...now to just sort out the minor leak at the filler pipe.



Steve

 

[CycloSteve]

OK, pulled the flap-valve out of the filler neck, and voila the o-ring had been pinched by the previous owner (the one who traded their Egyptian 80 in for Cash4Clunkers). Also found that the flap had been missing one of the pivots for some time...the reason why it was a bit sticky when pulling the changover lever.

So, I have an eMail out to Dave from Japan4x4 to see if he can get the o-ring and the proper pin...in the meantime, looking at just buttoning her back up using some Loctite 518...which appears to be the right thing for this application, and I have a nice 50ml tube ready to go.



Steve

 

[70sguy]

Doesn't look like the O-ring is available separately.
Might have to FIPG it

 

[tlc1995]

how much cutting of the header did u have to do to fit the overhead consule?

 

[S.CarolinaFZJ80]

I got my wiring all sorted out last night. After going through and rechecking EVERYTHING I realized that the instructions in one of the previous post led me astray. The Sub Tank Switch pin 6 goes to ground wire, (white/black) not 12V+ (gray)from the cigarette lighter.
Figures it was the last thing to check and the ONLY problem with my wiring. Anyway, works as advertised. I will post up an enhanced wiring diagram, specific to my 1996 model year.

 

[CycloSteve]

Sam, great to hear yours is now operational.

Used Loctite 518 FIPG today so that it is buttoned-up for now. The diagram above looks to be for the newer-style neck, not the early 80 series design, as the layout of quite a bit of that one looks different from mine. Will see if Dave can dig up anything from Japan.

*EDIT* Dave confimed that the gasket is not available, just the whole lower assembly, ouch! I am also replacing the lost "pin" with a longer one from McMaster Carr which replaces both pins.



Steve