OEM Subtank Retrofit/Install Project With Pics

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Got my hands on a couple of 80 series dual filler necks.
One early type, one late. Anyone have some hands on experience installing both types?
Trying to figure out what the implications of the different angles are... Late type use hoses with preformed bends or something?
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Mine is the earlier design with the straight hoses going to the Main and Sub tanks. My "setup" even came with said hoses which were in perfect shape, even after all these years. These hoses even had steel inserts which made them very stiff in the middle sections, yet softer at the ends. Not your standard hose, for certain. Installation was quite easy, as it bolted right into place and the lines slipped right on (with a little heating to loosen them up).

With the newer version, you definitely will need to find longer fuel-rated hoses with the proper bends, especially with the line which goes to the Sub, as that appears to have much more of a change of angles. Looking at the pictures, it appears that the hose needs to be slightly bigger? Hopefully one of the members who has installed the later version will have some good sources / tips for the plumbing bits they have used.

Personally if you have both, I would install the earlier version and flog the later one to a fellow Mudder FWIW.

:cheers:

Steve
 
Thanks Steve, too late...the older version is my bud Gregs already... going on his 94 FZJ
I went with the later filler since mine is a 97, 95/01 seems to be where the dual filler neck and lower filler pipe part numbers change.
So I figure there is something different in either the Lower filler tube assy at the dual filler neck end, or the later type uses formed rubber hoses with a bit of a bend at the dual filler valve end.
Anyway if you gots some hands on with the later style filler neck/hoses/tube assy.. help a brother out.
 
Ahh... I think I may have found my answer hidden in one of S.Carolina's pics
That looks like a bend at one end of the rubber pipe..

Let me know how that install goes S.Carolina, and if that bend makes up for the less than 90deg at the bottom of the late model dual filler neck.
80 Dual filler.webp
 
Here are the later hose numbers, I believe.

77259-60122 from neck to main hard-line
77259-60111 from neck to sub
77213-60090 from main hard-line to main

I would contact Dave at Japan4x4 to see if he can verify and get them for you.

:cheers:

Steve
 
Sweet, thanks Steve.
I will double check em on Toyota EPC. If the part numbers for the earlier neck to main hard line
and neck to subtank are different number then that will confirm what I suspect.
 
Numbers look good. Different for pre/post 95/01 so that is likely where the difference in the angle is made up. Will be ordering a bunch of stuff from Dave pretty quick.
 
Ahh... I think I may have found my answer hidden in one of S.Carolina's pics
That looks like a bend at one end of the rubber pipe..

Let me know how that install goes S.Carolina, and if that bend makes up for the less than 90deg at the bottom of the late model dual filler neck.

Hey! I recognize that picture! You are correct 70sGuy, that hose does match up perfectly to my '96 GXL filler neck (post #64) and sub tank. However, as Steve mentioned, it was a bit stiff and needed to be heated up to slip on the filler and sub tank ends. I think it was the original hose due to its condition but I have had no issues as of yet.

I should order a replacement to keep on hand, just in case.
 
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I'll be ordering all new hoses from Dave.
Thanks!
 
I had to take a few weeks off from this project, but getting back to it.

There is no way on earth I will ever be able to read a schematic. If I figure it out in advance, then have somebody hold my hand, I can hardly understand a EWD. In spite of my stupidity, I am trying to figure out the kick panel connections.

#1 is the ABS ECU, so just look at the plugs with alpha labels for the following questions.

Can somebody tell me which plug(s) have the wires running from the ECU in the back of the cargo area?

Same question, can somebody tell which plug(s) have the wires from the sub tank sending unit ?

Several narratives mention connecting to the "charge light on the combination meter". What the he!! is that ???

Where do I tap in to get 12v to the rear ECU?

Where do I tap in to get 12v to the rear sending unit?
Begining_Kick_Panel.webp
 
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AK I will be back in the US tomorrow and send/post a copy of my install worksheet. If you have the EWD it does help in finding the right pins to pull and relocate to the "new" plug.

IIRC also the subtank wires appear on one side of the plugs, and not the other and do not appear in the US EWD.

You will pull power from the fuse panel just above.

The Charge Light wire is tapped behind the instrument cluster. It is optional, but helpful with pulling codes if the system is not working.

More info tomorrow.

:cheers: from London

Steve
 
You will have to open those connectors up in order to identify.

The answers to your questions about which plug is what are outlined in posts #29 & 32 in text.

Post #'s 171 & 184 give you a graphic depiction.

When you hook up the Sub transfer system to the charge light on the combination meter (your dash cluster), it simply keeps the pump from operating when you have a weak battery (i.e charge light illuminated) thus draining it more. This is not required and not needed. I don't have it hooked up.

The DLC wire pictured in post #77 gives you the ability to self diagnose using the DLC connector under your hood. If correctly connected, you jumper two pins in the connector and it will cause a light on your sub dash switch to blink. The frequency of the blinking identifies various problems.

El Mariachi, the creator of this mod sent me a bunch of info. I will email it to you.
 
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The DLC wire pictured in post #77 gives you the ability to self diagnose using the DLC connector under your hood. If correctly connected, you jumper two pins in the connector and it will cause a light on your dash to blink. The frequency of the blinking identifies various problems.

Specifically, the blinking light will be the light on the subtank switch. So you have to have it wired up and everything in place to be able to use it to diagnose the circuit.

Can somebody tell me which plug(s) have the wires running from the ECU in the back of the cargo area?

A, B and C are the three plugs I reference that all have the donor wires from the BACK OF THE TRUCK. Each truck is different for whatever reason so it hasn't been well documented "plug 1, pins 2,4,6,8 etc). That's why you have to get into the rationale of understanding the diagram. This is not plug and play.

Same question, can somebody tell which plug(s) have the wires from the sub tank sending unit ?

The easiest way to confirm this is to have someone ground out the yellow/red wire at the subtank ECU connector over to the frame using a short wire. Then go up front in those three plugs, disconnect the two that are plugged in and start ohming out all the yellow/red wires with a voltmeter. The one yellow/red wire that beeps is the wire coming from the tank (because its grounded out). Its either yellow/blue or yellow/red.

Several narratives mention connecting to the "charge light on the combination meter". What the he!! is that ???

The fuel transfer ECU in the back would like to see a signal from the charge/alternator light bulb that lights up when the battery is weak or alternator is failing. It wants to be able to stop a fuel transfer in that case. You don't need this right now so skip it.

Where do I tap in to get 12v to the rear ECU? Where do I tap in to get 12v to the rear sending unit?

You tap in to the 12V in the driver' side fusebox. I know you don't think you can read schematics, but you need to follow me here:

If you look at the wiring diagram back in post #1, at the bottom in the lower middle section you'll see the "fuel tank changeover switch". On the lower left of it you'll see a yellow wire leaving pin #4. It says it goes to the "Gauge" fuse, which is in the driver's fusebox. That's where you get 12v+ for the front switch circuit. The rear system already has 12V on it in those three connectors you are messing with. How do we know this? Because in looking at that same schematic, you'll see leaving the upper left of the ECU connector box in the middle of the page a black/red wire headed to the fusebox. Its already in the side harness and runs through one of those three connectors up to the fusebox. Via that existing wire and power source the sending unit is already powered.
 
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Well I think I have all the under dash wiring done. Next will be to plug in the various components, and see if they work, see if I did the a
Wiring correctly.

Some of the exterior connections have been dragged through the mud and road salt For the last 15 hrs. How is the best way to clean these external plugs? Just to ensure I don't have shorts and bad connections.
 
Good to hear that you got the wiring done. Don't forget to diagnose per the Aussie FSM pages I sent you.

All of the unused plugs under my rig were impacted with mud and grime.

I used a small, hand held steam cleaner (bought at a drug store) to clean the exposed, dirty connectors.
After steam cleaning them, let them dry throughly, then use some dielectric grease when you plug them into their new connections.
 
Some of the exterior connections have been dragged through the mud and road salt For the last 15 hrs. How is the best way to clean these external plugs?

Spray them clean with a can of ether/starter fluid, then lube liberally with dielectric grease.
 
dual tank in a diesel

Hi Guys,
I am going over these threads and I am a bit baffled by all the wiring issues.

I do have first some basic questions: The truck is a 96 FZJ80 converted to a 1HDT. I assume the ECU is from the australian donor truck.

The system I have for the aux sub thank has:
-the tank with straps
-the dual filler neck
-the oem transfer pump (unfortunately the plastic fuel-in nipple on the solenoid is broken off-can the solenoid be purchased separately?)
-various male and female connectors
-the overhead console with fuel level and altimeter
-a sub-switch (not sure which one, seems to have 6 connectors)
-one of Gerorge's ECUs

What I want: be able to transfer diesel from the aux to the main tank and have the overhead console functioning.
I do not care about the 75% cut off, nor do I care about the OEM transfer pump.

As far as I understand it, the fuel level indicator/altimeter system should be independent of the transfer pump assembly. Is that correct?
Could I just (attempt to) wire in the level indicator and overhead console, and then just run an aftermarket transfer pump?

Of course I have no clue what plugs the (original US 96) truck has and what is in the diesel wiring harness.

I might be in over my head here.

thanks,
cheers,
jan
 
Hi Jan,

Looking at the materials you have in hand I would recommend doing an OEM/Georges "hybrid" type of installation. The big piece missing to do the OEM setup is the OEM main tank or going with one of the weld-on rings from elMariachi (Jim).

The setup I would pursue in your case with a diesel motor would be the following:

1. OEM subtank (duh)
2. Non-OEM transfer pump (sell the OEM transfer assembly as it is overkill for your setup)
3. Plumb #2 to the vent line to the main tank, as several others have done
4. Use Georges' ECU with OEM switch on dash
5. Install and enjoy the OH console with Alti and level as it only gets the level-signal from the sub sensor (or sell to me if you do not want) ;)

Since yours is a gasser-chasis, you should follow the gasser instructions in this thread. IIRC the diesels are set up completely different, but you do not have any of that wiring in the chasis.

BTW, you may want to let us know where you are located, as there may be someone in your local area who can help.

:cheers:

Steve
 

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