180L Replacement Hi Capacity Fuel Tank

Yes, from 2015 we supply an additional carbon canister in our kits, these are mounted inline with the OEM canister to boost the amount of carbon used to help capture the larger volume of hydrocarbons created from a much bigger tank and assist in a cleaner environment.
Any tank supplied in Australia from 2015 must be installed with a canister to make it legal.

No, Long Ranger have designed these canisters to work with our specific designs and are only supplied complete with our tanks.

For a standard OEM twin tank setup in a 200 series:

When the Landcruiser 200 series has the factory twin tank option both tanks are filled via the one filler with a T-junction distributing a portion of fuel to both tanks until full.
Fuel is drawn from the main 93lt front tank by the engine’s fuel pump and a small electric transfer pump is mounted inside the main tank, which transfers fuel from the 45lt rear sub tank. This pump is not mounted directly inline but has a venturi device fitted, this means it is designed to suck virtually all the fuel from the sub tank with out pump failure because in theory can never run dry as it is being lubricated and kept cool by the fuel in the main tank.
The standard Toyota system has a sender unit in both tanks.
The system only has one Gauge
The low warning light is only in the main tank ( and normally comes on solid, if it flashes there is an issue with fuel transfer from the rear sub tank that needs to be fixed).
The Toyota 200 series Landcruiser owner’s manual states that when the warning light comes on in models with a factory sub tank there is about 20L or less left, and in single tank models there is about 15L or less.
The fuel is transferred automatically from the rear tank to the front tank. (you have no say in the matter)
The transfer pump (jet pump) is mounted in the bottom of the main tank.
It is not an inline type pump but recycles the fuel in the bottom of the main tank and the fuel is sucked over from the sub tank via a venturi effect. This is very simple and the pump will never run dry unless the main tank is dead empty.
If the vehicle has a trip computer with distance to empty (DTE), the actual driving range is a calculation of the factory tank capacity (to the empty mark) and the recent average fuel consumption and cannot be changed when a bigger tank is installed. So the computer will always think the system has the original fuel tank size and calculate the DTE based on this fact (it’s a bugger, but unless someone is smart enough to get into the Toyota setup and alter the tank size it ain’t going to be possible to change).

Some other facts:
The one gauge reads the combined contents of both tanks
The transfer pump is operated by the position of the sender in the sub tank, so:
The transfer pump is automatically turned on while ever the sub tank sender is registering fuel in the tank.
The Transfer pump is turned off automatically when the sub tank sender registers empty.

Some points to note:
*When filling the vehicle you have no choice which tank the fuel goes into, but about 80% should go into the main tank till full with the remainder going into the auxiliary.  So if you only partially fill the tanks, some will end up in the rear sub tank.
*When using your vehicle you have no choice as to which tank you use fuel from.
*The gauge on the dash reads the first two thirds for the main 93lt tank and the top third for the rear 45L sub tank.  So as you drive along after filling both tanks, when the gauge reads approx. 2/3 you will have used all the 45L of fuel from the rear tank and when the gauge reads approx. 1/3 you will have about half the main tank left or 45L.

Please click here to view to our animation to assist in explaining this.

Explanation of the system after The Long Ranger has been fitted:
When a Landcruiser 200 series has been fitted with a Long Ranger Fuel Tank the system is not altered in any way other than a larger sub tank, the capacity will depend on which model you have chosen (70L, 90L, 122L or 180L).
So the gauge still reads the same and the fuel filling and usage by the engine is unchanged. And the trip computer still only computes the driving range based on the original tank capacity,  not the new larger capacity.

The best way to understand this is to think of the gauge as a two part gauge.
The top one third reading the rear tank and the bottom two third’s reading the front main tank.  Unfortunately we are unable to alter the factory computer settings and gauge to allow for a new bigger tank.
Please click here to view our animation for an indication of how to interpret and calculate the fuel you have remaining.

Some points to note:
* The driving range is still only a calculation of the factory tank capacities, not the new larger capacity.
* When the gauge reads two thirds you have used the entire sub tank and have the main 93L remaining.

The low warning light when the fuel system is working correctly will come on as a solid light when the gauge approaches empty.
When the main tank is low, but there is a fault with the fuel transfer system the gauge will have a reading to represent the fuel in the rear tank, but the warning light will flash to signal a fault and the fact the main tank is about to run out of fuel.
Although this issue in uncommon below is some information we have compiled over the years to help those that have found themselves in this situation and it is very important for the user to understand when the low warning light flashes the system knows something is wrong (this is written in the owners manual), in the case of the light coming on and flashing when gauge is still on about 1/4 it knows the front tank is nearly empty but there is fuel in the back tank that can not be used.  In this case the engine will shortly have no fuel supply and the vehicle will stop because the fuel gauge is reading the contents of the rear tank yet the front main tank is empty!

If the tank has been in a while and working fine :
1. Here is an Lcool link to the thread about the wiring issue which results in the symptom of a flashing light because the main tank is almost empty and fuel remains in the sub tank, Although I think they changed it so only members can view post.
http://www.lcool.org/forum/viewtopic.php?t=35430&postdays=0&postorder=asc&start=150&sid=f8c4035b8b42ce8396b6539108654e45
2. The jet pump may be blocked or malfunctioning
3. The rear sender is malfunctioning

If a new longranger tank has just been fitted then it is most likely something to do with fitting or tank
1. Hoses incorrectly plumbed
2. Sender unit extension not done correctly
3. Sender wire not connected or squashed
4. The pickup on the long Ranger may not have the internal pipe going all the way to the bottom.

It should be checked that the hose from the Long Ranger pickup is followed all the way to the top of the main tank If it goes to the front of the main tank or the engine bay it has been incorrectly plumbed to a return line.

A couple of points to note if a bigger tank has been fitted and not done correctly.
1. In the longranger kit, a new float arm is supplied because the new tank is much deeper than the OE tank.
If this is not done the sender may prematurely read empty and the pump will be turned off automatically leaving a large amount of fuel in the tank.
If the float arm falls off, the sender will always read empty and the system will never turn the transfer pump on. An indication of this will be the gauge only gets to about two thirds full after filling both tanks.
If the electrical plug is not connected properly for the sender unit, the fuel will not be used from the sub tank and the gauge will give unusual readings and never reach full.
2. There are three pipes going to the pickup unit in standard tank. When fitting a bigger tank only one of these is used for the pickup and the others are not required.
If the wrong pipe is used or if the OEM transfer system fails for some reason, no fuel or very little fuel will be used from the rear sub tank. You will know this because the gauge will get to about 1/4 empty very quickly after only traveling enough distance to use only the main tank (90lt)
This may also cause the gauge a few problems as it is reading the combined contents of both tanks to give the user one reading. Because the rear sub tank sender will be registering fuel, but the front tank is going down the gauge will be reading more fuel than you have available (as the rear sub fuel tank fuel is unusable due to incorrect plumbing or possible other faults) and therefore the vehicle will run out of fuel before the gauge gets to empty.

All the above are different issues but the failure of fuel to transfer is the same result, there are many symptoms which can lead us to the correct solution
1. Does the fuel gauge go to full when filled or does it only go to about 3/4 full.
2. Does the car run our of fuel before it gets to empty
3. Is the low light flashing or solid (either way a low light means you need to fill up very soon) the flashing light indicates an issue with the transfer
4. Has a new Long Ranger just been installed.
5. Has the system been working fine for some time and stopped all of a sudden

With either the Long Ranger Auxiliary tank or the factory sub tank option it is simply just not economical to modify the system to run on either tank independently and tampering with the sophisticated electronics may lead to all sorts of problems.

Yes, to maximise fuel usage from the new larger tank we have baffles and a built in chamber around the fuel pickup unit to help avoid pickup cavitation sucking in air, these features can be especially useful when accidentally running low on fuel or driving on sloping terrain.
With larger tanks having bigger surface areas baffles also help add strength for those odd knocks and dents you can’t avoid.

Yes, although some OEM and aftermarket tanks don’t come fitted with a drain plug we believe this is a must have feature when traveling the outback as you never know if you have to drain the tank in the advent of picking up a bad load of fuel.

Yes, an ADR compliant valve is supplied in the kit and fitted during the installation.
This keep you safe and your car working the way the manufacturer intended it to in the event of a serious accident.

Although most aftermarket manufacturers only build one tank to suit both models for a longrange tank to be legal in Australia and most other countries around the world all road registered petrol engine vehicles need to be fitted with an additional carbon canister to ensure their anti pollution systems continue to comply with the regulations for vehicle registration, from 2015 The LongRanger is the only legal tank in Australia with our kits  supplied standard with a carbon canister.

While the fuel gauge will still work and be consistent with it’s new readings, due to the shape we have made the tank to maximise the capacity under the vehicle the gauge will stay on full for longer and the top half of the tank is bigger than the bottom half.
If we cant modify the OEM sender to suit the new tank our kits are supplied with a longer direct replacement float arms to improve the accuracy, this speeds up the fitting time and no soldering or brazing on wire extensions to the OEM float arm.

Generally we try to make our tanks fit with most towbars on the market at the time we design our tank, occasionally a particular towbar is built in such a way that to make our tank compatible would result in very little extra fuel capacity gained,  if there are any known issues with specific models we mention this on the specifications tab under “other mods”

While there is a popular belief that all the big brands are made in a country with a cheap manufacturing base in the same factory with a different badge at The Long Ranger we still design and manufacture our tanks in Australia were it all started way back in the late 70’s.  We are a family run company based in Newcastle employing local people and that’s not about to change anytime soon.

No, adding a tank is the same as any other accessory and is utilising the vehicles payload capacity IE: anything added to the vehicle from the manufactures specification is using the payload capacity, whether it be driving lights, a set of rubber mats, a LongRanger fuel tank or the kids. As with most vehicles from a manufacturer the standard springs are not designed to cope with a constant full load on an extended trip, we recommend fitting a set of heavier rated springs such as those from Old Man Emu that have been designed to carry the extra weight of a fully loaded vehicle set up for camping.

Yes they do, you may have heard on the grape vine that some aftermarket tank suppliers ship their products with poor fitting instructions and incomplete kits that make a trip to the local auto store a necessity to finish the job. At the LongRanger we supply comprehensive installation instructions with lots of photos to ensure the job is done as efficiently as possible and a complete installation kit ready to install so your local fitter can be rest assured there will be no expensive delays sourcing bits and pieces to finish the job!

Standard OEM fuel tanks manufactured with plastic construction or thin turn plate often require an extra bash plate for protection. Being made from 2mm “aluminised steel” with internal baffling our tanks are designed to handle the odd scrap and dint you would expect with general 4wd use or outback touring and offer excellent strength and durability in these situations. Depending on your intended vehicle use if you often find when out on the trail turning back is not an option and your forced to test your vehicle to it’s limits or if you’ll be doing lots of hard off roading in steep and rocky terrain we may have other options more suitable for you such as a smaller tank with more ground clearance or a “HD” version with a heavy duty protection plate welded directly to the bottom of the tank.

There is nothing worse than buying an accessory to find it’s not compatible with something else you have fitted, we might not be first to market, but that’s because we try our best to design our long range tanks to be suitable with all models in the range and most other popular accessories you might want to install either now or in the future. Although we have designed our tanks with maximum compatibility in mind, if you have something specially fitted to your vehicle that is of concern we have provided a good selection of pictures in the gallery showing the installation to give a clear idea where The LongRanger fits under the vehicle.

If you can’t make it to the Newcastle factory at 65 Northville Drive Barnsley NSW, all our products are distributed by ARB 4×4 accessories. For sales and support around Australia you can find a list of all the ARB stores Here

All LongRanger manufactured products are covered by a 3-year warranty.
Note: There are some third party components not made by The LongRanger such as fuel pumps, sender units and switches etc found in some kits that come with their own 12 month manufacturers warranty.

All LongRanger fuel tanks are made from Aluminised steel. This product is manufactured by the steel mill using 2mm (14gauge) cold rolled steel with a thin aluminium coating applied during the manufacturing process. Aluminised steel offers excellent weight vs. strength and durability when compared to lighter aluminium that just doesn’t have the raw strength to stand up to the hard knocks the underneath of a vehicle can suffer or the heavier Stainless steel that is more prone to fatigue cracks caused by embrittlement in the heat affected zone from the welding process.