Installing a 50l auxiliary diesel fuel tank above the spare wheel, between the chassis legs, of my 2012 Toyota Fortuner 4X4 SUV.

This post is an overview of my experience and the issues and difficulties in the installation process. This may help others in deciding whether to perform a similar DIY installation on their own 4X4 or to purchase a professional installation. This post has taken me over two years to complete, so some of the issues I experienced have been excluded.

Purchased Item

Front Runner recently discontinued their 42l auxiliary fuel tank that fitted the 2005 – 2015 Toyota Fortuner and replaced it with the above pictured 50l auxiliary fuel tank that fits the older models and the current model Toyota Fortuner.

An update to the Front Runner website now shows that the new fuel tank is manufactured by Gerber 4X4:

Alternatives

Exel Long Range fuel tanks – Manufactured by Northern Offroad and supplied to all 4X4 Megaworld and Safari Centre stores in South Africa

Installation

The kit comes with installation instructions – but these are rather basic and appear to miss steps (or sufficient images) to understand how to perform parts of the install.

Issues experienced

Towbar

The towbar that was fitted to my vehicle was incompatible with the auxiliary fuel tank – there was insufficient clearance between the towbar square tubing behind the bumper and the tank. Luckily, I was able to source a different style of towbar that also fitted my vehicle – tolerances were very close, but the shape and round tubing of the new towbar allowed the fitment to continue after some minor persuasion with a large hammer.

Brake lines

There does not appear to be any tolerance or space between the new tank and the rear brake line pipe. A spacer is required to keep the two parts from rubbing.

Spare wheel lock

Although a large space is placed in the tank to allow the spare wheel chain to still function and carry the spare wheel – the space is insufficient to utilize most under vehicle spare wheel lock systems. I had to permanently remove my spare wheel lock to fit the new fuel tank.

Exhaust Pipe

There is no space between the exhaust pipe and the fuel tank. When you turn on the vehicle the exhaust vibrates loudly against the new tank. a visit to an exhaust specialist was required to re-route the last 1m section of exhaust pipe after the muffler away from the tank.

Provided instructions

The instructions and images provided are limited – with assumptions and guesses needing to be made on where to cut or remove existing fuel hoses (both for the filling line to the fuel tanks and for joining the new tank with the existing tank)

Insufficient fuel hose

Maybe this is related to the instructions issue above, but I was supplied with around two meters to little fuel hose length than I required to connect all the components as per the instructions.

Conclusion

I regret not completing this post during the installation processes or shortly after as I would have a more complete overview of all the issues and concerns I had with performing this installation as a DIY task.

Although I have listed many issues with the DIY installation above, the install was still successful, and it has now been in use for over three years without issue.

Would I purchase the same auxiliaryfuel tank again?

Yes.

Would I perform the installation myself again?

Even with my knowledge on the process, I would not – I would budget the extra amount required and have it installed by the professionals.