Watch me rebuild my entire fuel system

[FJ40Jim]

No, it shouldnt leak a drop.

To find leak, have helper lightly pressurize tank by putting air blow gun into fill neck and lightly restricting air escaping from neck with a rag. Spray windex on joints, llook for bubbles.

 

[bmorefj40]

I know where it's leaking. It coming out around the edges of the fuel sender. It's very apparent. No leak testing needed. How do I get a proper seal? Is there a sealant I should have used around the fuel sender above and/or below the gasket, or do I just need to crank down on the retaining screws?

 

[FJ40Jim]

Should be flat sender sitting on the flat reinforcing ring. With a new (soft) rubber gasket, it doesn't need a lot of tork to get a seal. Hence the tiny phillips screws. Be aware that the screw holes are very short, so if the screws are 1mm too long, they will bottom out in the hole before actually crushing the gasket.

No sealant should be used. Most sealants will wash away over time.

 

[bmorefj40]

Uh ohh. Think I know my issue. I used the screws from the sender I got with an old tank. They were pretty long.... Think I may have driven them too far and gone through the seal below. Is there a fix for this or did I totally mess up a brand new tank....

 

[bdhelpaso]

Thanks fj401978, picked up some 1/4" tubing and new clamps. ready to get into this once my tank arrives.

Does anyone know of any other goodies that I should pick up before I tear into this? I'll need to try and wrap this up in one day. Once I start, I'll be stranded until I get it all back together and working, since I'll be doing this at my shop.

I checked the Toyota manuals and couldn't find a section that talked about tank, fuel separator, and charcoal canisters. So, either there is another manual that I need to get or mine is for an older model and doesn't cover it. I've just been using advice here and pictures on sor/ccot to get all the pieces I need.

Is the fuel line coming out of the bottom of the tank going to the fuel pump 5/16" or 1/4"? I have a 1978 FJ40.

 

[bmorefj40]

Don't have my truck in front of me, but 1/4", I believe. I bought a roll of both 1/4" and 5/16" to do the fuel line and some of the emissions hoses too. Had a bunch of 5/16th leftover, not too much left of the 1/4". 25ft rolls of each. Once I get home I can confirm.

 

[WB8LBZ]

I used a stainless braid hose from the bottom of the tank out the bottom of the body to the filter/fuel pump to the second fuel filter - pressure gauge - fuel regulator. I live up in the Northeast if you would like to stop by to take a look.

Larry in El Paso

 

[bdhelpaso]

I used a stainless braid hose from the bottom of the tank out the bottom of the body to the filter/fuel pump to the second fuel filter - pressure gauge - fuel regulator. I live up in the Northeast if you would like to stop by to take a look.

Larry in El Paso

sure. Wouldn't mind seeing your rig. How do I get a hold of you?

 

[WB8LBZ]

Check in the conversations area. Most nights after 5-5:30.

Larry in El Paso

 

[FJ40Jim]

Is the fuel line coming out of the bottom of the tank going to the fuel pump 5/16" or 1/4"? I have a 1978 FJ40.

The fuel feed & return lines are 5/16"/8mm OD steel line. Fuel hoses are 5/16 ID hose.

The fuel tank vapor hoses to the canister are 1/4"/6mm