Urea Tank Removal


  1. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)

  2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

  3. REMOVE NO. 1 FRONT FENDER APRON TO FRAME SEAL LH

  4. DISCONNECT NO. 3 FRAME WIRE

  5. DISCONNECT UREA TUBE WITH HEATER ASSEMBLY

  6. DISCONNECT UREA TANK BREATHER TUBE SUB-ASSEMBLY

  7. DISCONNECT UREA TANK FILLER TUBE SUB-ASSEMBLY

  8. REMOVE UREA TANK SUB-ASSEMBLY

  9. REMOVE UREA TANK BREATHER TUBE SUB-ASSEMBLY

  10. REMOVE UREA TANK FILLER TUBE SUB-ASSEMBLY

  11. REMOVE UREA TUBE WITH HEATER ASSEMBLY

  12. REMOVE UREA PUMP

  13. REMOVE NO. 1 UREA TANK BRACKET

  14. REMOVE NO. 2 UREA TANK BRACKET

Urea Tank -- Removal



1. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)
(LandCruiser RM00000178S015X.html)


2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)
(LandCruiser RM0000013F601RX.html)


3. REMOVE NO. 1 FRONT FENDER APRON TO FRAME SEAL LH

  1. Remove the 5 clips and No. 1 front fender apron to frame seal LH from the body.



4. DISCONNECT NO. 3 FRAME WIRE


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Disconnect the connector from the urea tube with heater assembly.

  1. Detach the clamp from the urea tank sub-assembly.



    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Pull the tabs of the connector as shown in the illustration and disconnect the connector from the urea pump



5. DISCONNECT UREA TUBE WITH HEATER ASSEMBLY

  1. Disconnect the urea tube with heater assembly from the urea injector set (LandCruiser RM000005UKV000X_01_0001.html).



    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Detach the 2 clamps and disconnect the urea tube with heater assembly from the frame crossmember.



6. DISCONNECT UREA TANK BREATHER TUBE SUB-ASSEMBLY
NOTICE:
Check for dirt or mud on the urea tank filler pipe and around the urea tank breather tube connector before disconnection. Clean if necessary.


  1. Disconnect the urea tank breather tube sub-assembly from the urea tank filler pipe assembly.



      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Gd-Ftv Emission Control.Emission Control System.Urea Tank Removal

    1. Detach the claw of the retainer of the urea tank breather tube connector, pull up the retainer and disconnect the urea tank breather tube connector from the urea tank filler pipe assembly.

      NOTICE:
      1. If there is any solidified urea solution (white solids) on the connection area, clean the solids off with a damp cloth, etc., before disconnecting the connector.
      2. Be sure to disconnect the urea tank breather tube connector by hand.
      3. Check for foreign matter in the urea tank filler pipe assembly and around the urea tank breather tube connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the urea tank filler pipe assembly and urea tank breather tube connector.
      4. Put the urea tank filler pipe assembly and urea tank breather tube connector ends in plastic bags to prevent damage and foreign matter contamination.
      Text in Illustration
      *a
      		Retainer
      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
      		Pull
      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
      		Pull Out


7. DISCONNECT UREA TANK FILLER TUBE SUB-ASSEMBLY
NOTICE:
Check for dirt or mud on the urea tank filler pipe and around the urea tank filler tube connector before disconnection. Clean if necessary.


  1. Disconnect the urea tank filler tube sub-assembly from the urea tank filler pipe assembly.



      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Gd-Ftv Emission Control.Emission Control System.Urea Tank Removal

    1. Pinch the retainer of the urea tank filler tube connector, and then pull the urea tank filler tube connector off of the urea tank filler pipe.

      NOTICE:
      1. If there is any solidified urea solution (white solids) on the connection area, clean the solids off with a damp cloth, etc., before disconnecting the connector.
      2. Be sure to disconnect the urea tank filler tube connector by hand.
      3. Check for foreign matter in the urea tank filler pipe assembly and around the urea tank filler tube connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the urea tank filler pipe assembly and urea tank filler tube connector.
      4. Put the urea tank filler pipe assembly and urea tank filler tube connector ends in plastic bags to prevent damage and foreign matter contamination.
      Text in Illustration
      *a
      		Retainer
      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
      		Push
      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
      		Pull Out


8. REMOVE UREA TANK SUB-ASSEMBLY


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the 2 bolts and urea tank sub-assembly from the flame LH.



9. REMOVE UREA TANK BREATHER TUBE SUB-ASSEMBLY
NOTICE:
Check for dirt or mud on the urea tank sub-assembly and around the urea tank breather tube connector before disconnection. Clean if necessary.


  1. Detach the clamp and remove the urea tank breather tube sub-assembly from the urea tank sub-assembly.



      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Gd-Ftv Emission Control.Emission Control System.Urea Tank Removal

    1. Detach the claw of the retainer of the urea tank breather tube connector, pull up the retainer and disconnect the urea tank breather tube connector from the urea tank sub-assembly.

      NOTICE:
      1. If there is any solidified urea solution (white solids) on the connection area, clean the solids off with a damp cloth, etc., before disconnecting the connector.
      2. Be sure to disconnect the urea tank breather tube connector by hand.
      3. Check for foreign matter in the urea tank sub-assembly and around the urea tank breather tube connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the urea tank sub-assembly and urea tank breather tube connector.
      4. Put the urea tank sub-assembly and urea tank breather tube connector ends in plastic bags to prevent damage and foreign matter contamination.
      Text in Illustration
      *a
      		Retainer
      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
      		Pull
      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
      		Pull Out


10. REMOVE UREA TANK FILLER TUBE SUB-ASSEMBLY
NOTICE:
Check for dirt or mud on the urea tank sub-assembly and around the urea tank filler tube connector before disconnection. Clean if necessary.


  1. Detach the clamp and remove the urea tank filler tube sub-assembly from the urea tank sub-assembly.



      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Gd-Ftv Emission Control.Emission Control System.Urea Tank Removal

    1. Pinch the retainer of the urea tank filler tube connector, and then pull the urea tank filler tube connector off of the urea tank sub-assembly.

      NOTICE:
      1. If there is any solidified urea solution (white solids) on the connection area, clean the solids off with a damp cloth, etc., before disconnecting the connector.
      2. Be sure to disconnect the urea tank filler tube connector by hand.
      3. Check for foreign matter in the urea tank sub-assembly and around the urea tank filler tube connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the urea tank sub-assembly and urea tank filler tube connector.
      4. Put the tank sub-assembly and urea tank filler tube connector ends in plastic bags to prevent damage and foreign matter contamination.
      Text in Illustration
      *a
      		Retainer
      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
      		Push
      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
      		Pull Out


11. REMOVE UREA TUBE WITH HEATER ASSEMBLY
NOTICE:
Check for dirt or mud on the urea pump and around the urea tube connector before disconnection. Clean if necessary.

  1. Disconnect the urea tube with the heater assembly from the hose clamp.



  1. Remove the urea tube with heater assembly from the urea pump.



      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

    1. Detach the lock claw by lifting up the cover.

      Text in Illustration
      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
      		Lift Up


      2. Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

    2. Pinch the retainer of the urea tube connector, and then pull the urea tube connector off of the urea tube with heater assembly.

      NOTICE:
      1. If there is any solidified urea solution (white solids) on the connection area, clean the solids off with a damp cloth, etc., before disconnecting the connector.
      2. Be sure to disconnect the urea tube connector by hand.
      3. Check for foreign matter in the urea pump and around the urea tube connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the urea pump and urea tube connector.
      4. Put the urea pump and urea tube connector ends in plastic bags to prevent damage and foreign matter contamination.
      Text in Illustration
      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
      		Pinch
      Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
      		Pull


12. REMOVE UREA PUMP


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Gd-Ftv Emission Control.Emission Control System.Urea Tank Removal

  1. Set SST on the urea pump gauge retainer.

    SST
    09808-14030(09808-01030,09808-01040)
    HINT:
    1. Engage the claws of SST securely with the urea pump gauge retainer holes to secure SST.
    2. Install SST while pressing the claws of SST against the urea pump gauge retainer (towards the center of SST).


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Gd-Ftv Emission Control.Emission Control System.Urea Tank Removal

  1. Using SST, loosen the urea pump gauge retainer.

    SST
    09808-14030(09808-01010)
    NOTICE:
    Remove any foreign matter around the urea pump before this operation.
    HINT:
    Fit the tips of SST onto the ribs of the urea pump gauge retainer.

  1. Remove the urea pump gauge retainer.



    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the urea pump from the urea tank sub-assembly.



    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the gasket from the urea tank sub-assembly.



13. REMOVE NO. 1 UREA TANK BRACKET


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the bolt and No. 1 urea tank bracket from the urea tank sub-assembly.



14. REMOVE NO. 2 UREA TANK BRACKET


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the bolt and No. 2 urea tank bracket from the urea tank sub-assembly.