Fuel Tank Removal

Engine Hybrid System. Land Cruiser. Urj200, 202 Grj200 Vdj200
1Vd-Ftv Fuel. Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. PRECAUTION

  2. REMOVE FUEL TANK CAP ASSEMBLY

  3. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

  4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

  5. DRAIN FUEL

  6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  7. REMOVE REAR NO. 1 SEAT ASSEMBLY RH (for 60/40 Split Seat Type 40 Side)

  8. REMOVE REAR NO. 1 SEAT ASSEMBLY LH (for 60/40 Split Seat Type 60 Side)

  9. REMOVE REAR NO. 2 SEAT ASSEMBLY

  10. REMOVE REAR NO. 1 SEAT PROTECTOR

  11. REMOVE REAR NO. 2 SEAT PROTECTOR

  12. REMOVE REAR STEP COVER

  13. REMOVE REAR DOOR SCUFF PLATE LH

  14. REMOVE REAR DOOR SCUFF PLATE RH

  15. REMOVE REAR FLOOR MAT REAR SUPPORT PLATE

  16. REMOVE REAR SEAT COVER CAP (w/ Rear No. 2 Seat, except Face to Face Seat Type)

  17. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY LH

  18. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH

  19. REMOVE AIR DUCT PLUG (w/ Rear Air Conditioning System)

  20. REMOVE REAR AIR DUCT GUIDE (w/ Rear Air Conditioning System)

  21. REMOVE FRONT FLOOR CARPET ASSEMBLY

  22. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER

  23. DISCONNECT FUEL TANK RETURN TUBE

  24. DISCONNECT NO. 2 FUEL TANK BREATHER TUBE (for Single Tank Type)

  25. DISCONNECT NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)

  26. DISCONNECT NO. 2 FUEL TANK BREATHER TUBE (for Double Tank Type)

  27. DISCONNECT FUEL TANK BREATHER TUBE (for Single Tank Type)

  28. DISCONNECT FUEL TANK BREATHER TUBE (for Double Tank Type)

  29. DISCONNECT FUEL TANK TO FILLER PIPE HOSE (for Single Tank Type)

  30. DISCONNECT FUEL TANK TO FILLER PIPE HOSE (for Double Tank Type)

  31. REMOVE FUEL TANK SUB-ASSEMBLY

  32. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN TUBE (for Single Tank Type)

  33. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY, FUEL TANK RETURN TUBE AND NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)

  34. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

  35. REMOVE FUEL TANK TO FILLER PIPE HOSE

  36. REMOVE NO. 1 FUEL TANK HEAT INSULATOR

Fuel Tank -- Removal



1. PRECAUTION
NOTICE:
After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (Click here).


2. REMOVE FUEL TANK CAP ASSEMBLY


3. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 5 bolts and fuel tank protector.



4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Detach the fuel tube clamp.

  1. Disconnect the fuel tank main tube.



5. DRAIN FUEL

  1. for Double Tank Type:

    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

      NOTICE:
      Do not start the engine.

    3. Turn the intelligent tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the Intank Fuel Pump Relay.

      CAUTION:
      1. Do not smoke or be near an open flame when working on the fuel system.
      2. Secure good ventilation.

      HINT:
      Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal
      for Single Tank Type:
      Remove the fuel tube joint clip and disconnect the fuel tank return tube, and drain fuel from the port shown in the illustration.
      for Double Tank Type:
      If the fuel pump does not operate, remove the fuel tube joint clip and disconnect the fuel tank return tube, and drain fuel from the port shown in the illustration.


6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

  1. Disconnect the cables from the negative (-) main battery and sub-battery terminals.



7. REMOVE REAR NO. 1 SEAT ASSEMBLY RH (for 60/40 Split Seat Type 40 Side)

  1. Remove the rear No. 1 seat assembly RH (Click here).



8. REMOVE REAR NO. 1 SEAT ASSEMBLY LH (for 60/40 Split Seat Type 60 Side)

  1. Remove the rear No. 1 seat assembly LH (Click here).



9. REMOVE REAR NO. 2 SEAT ASSEMBLY

  1. for Face to Face Seat Type:
    Remove the rear No. 2 seat assembly (Click here).

  1. except Face to Face Seat Type:
    Remove the rear No. 2 seat assembly (Click here).



10. REMOVE REAR NO. 1 SEAT PROTECTOR


Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal

  1. Detach the 10 claws and remove the 2 seat protectors.



11. REMOVE REAR NO. 2 SEAT PROTECTOR


Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal

  1. Detach the 10 claws and remove the 2 seat protectors.



12. REMOVE REAR STEP COVER
HINT:
Use the same procedure for both rear step covers.


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Detach the 2 claws and remove the rear step cover.



13. REMOVE REAR DOOR SCUFF PLATE LH


Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the screw.

  1. Detach the 3 claws and 4 clips, and remove the rear door scuff plate LH.



14. REMOVE REAR DOOR SCUFF PLATE RH
HINT:
Use the same procedures described for the LH side.


15. REMOVE REAR FLOOR MAT REAR SUPPORT PLATE


Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Detach the 6 clips and remove the rear floor mat support plate.



16. REMOVE REAR SEAT COVER CAP (w/ Rear No. 2 Seat, except Face to Face Seat Type)
HINT:
Use the same procedure for both No. 1 luggage compartment trim hooks.


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal

  1. Using a screwdriver, detach the 3 claws and remove the rear seat cover cap.

    HINT:
    Tape the screwdriver tip before use.
    Text in Illustration
    *a
    		Protective Tape


17. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY LH

  1. w/ Sliding Roof:
    Remove the front quarter trim panel assembly LH (Click here).

  1. w/o Sliding Roof:
    Remove the front quarter trim panel assembly LH (Click here).



18. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH

  1. w/ Sliding Roof:
    Remove the front quarter trim panel assembly RH (Click here).

  1. w/o Sliding Roof:
    Remove the front quarter trim panel assembly RH (Click here).



19. REMOVE AIR DUCT PLUG (w/ Rear Air Conditioning System)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Detach the 2 claws and remove the plug.

    HINT:
    Use the same procedures for both sides.


20. REMOVE REAR AIR DUCT GUIDE (w/ Rear Air Conditioning System)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the screw.

  1. Detach the claw and remove the guide.

    HINT:
    Use the same procedures for both sides.


21. REMOVE FRONT FLOOR CARPET ASSEMBLY


Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. w/ Rear Air Conditioning System:
    Fold back the floor carpet.

    HINT:
    Fold back the floor carpet so that the air duct can be removed.

  1. w/o Rear Air Conditioning System:
    Fold back the floor carpet.

    HINT:
    Fold back the floor carpet so that the service hole cover can be removed.


22. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. w/ Rear Air Conditioning System:
    Remove the 2 screws and air duct.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the service hole cover.



    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal

  1. Disconnect the fuel pump and fuel sender gauge connector.



23. DISCONNECT FUEL TANK RETURN TUBE


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal

  1. Detach the fuel tube clamp.

  1. Pull up the retainer and disconnect both ends of the fuel tank return tube.

    NOTICE:
    1. Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
    2. Do not use any tools to separate the pipe and connector.
    3. Do not forcefully bend or twist the nylon tube.
    4. Check for foreign matter on the pipe seal surface. Clean if necessary.
    5. Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
    6. If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.


24. DISCONNECT NO. 2 FUEL TANK BREATHER TUBE (for Single Tank Type)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Detach the fuel tube clamp.

  1. Disconnect the No. 2 fuel tank breather tube from the body.



25. DISCONNECT NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal

  1. Detach the fuel tube clamp.

  1. Pull up the retainer and disconnect the fuel main tube.

    NOTICE:
    1. Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
    2. Do not use any tools to separate the pipe and connector.
    3. Do not forcefully bend or twist the nylon tube.
    4. Check for foreign matter on the pipe seal surface. Clean if necessary.
    5. Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
    6. If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.


26. DISCONNECT NO. 2 FUEL TANK BREATHER TUBE (for Double Tank Type)


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal

  1. Detach the fuel tube clamp.

  1. Pull up the retainer and disconnect the fuel tank breather tube.

    NOTICE:
    1. Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
    2. Do not use any tools to separate the pipe and connector.
    3. Do not forcefully bend or twist the nylon tube.
    4. Check for foreign matter on the pipe seal surface. Clean if necessary.
    5. Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
    6. If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.


27. DISCONNECT FUEL TANK BREATHER TUBE (for Single Tank Type)


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal

  1. Detach the fuel tube clamp.

  1. Pull up the retainer and disconnect the fuel tank breather tube.

    NOTICE:
    1. Do not use any tools in this procedure.
    2. Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.


28. DISCONNECT FUEL TANK BREATHER TUBE (for Double Tank Type)


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal

  1. Detach the fuel tube clamp.

  1. Pull up the retainer and disconnect the fuel tank breather tube.

    NOTICE:
    1. Do not use any tools in this procedure.
    2. Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.


29. DISCONNECT FUEL TANK TO FILLER PIPE HOSE (for Single Tank Type)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the hose from the filler pipe.



30. DISCONNECT FUEL TANK TO FILLER PIPE HOSE (for Double Tank Type)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the hose from the filler pipe.



31. REMOVE FUEL TANK SUB-ASSEMBLY

  1. Place a transmission jack under the fuel tank.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts, 2 clips, 2 pins and 2 fuel tank bands.

  1. Lower the transmission jack to remove the fuel tank from the vehicle.

    NOTICE:
    Do not allow the fuel tank to contact the vehicle, especially the differential.
    HINT:
    Lower the transmission jack slowly.


32. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN TUBE (for Single Tank Type)


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal

  1. Remove the 2 fuel tube joint clips and pull out the 2 fuel tubes.

    NOTICE:
    1. Remove any dirt and foreign matter on the fuel tube joint before performing this work.
    2. Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
    3. Perform this work by hand. Do not use any tools.
    4. Do not forcibly bend, twist or turn the nylon tube.
    5. Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 fuel tubes from the fuel tank.



33. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY, FUEL TANK RETURN TUBE AND NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal

  1. Remove the 3 fuel tube joint clips and pull out the 3 fuel tubes.

    NOTICE:
    1. Remove any dirt and foreign matter on the fuel tube joint before performing this work.
    2. Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
    3. Perform this work by hand. Do not use any tools.
    4. Do not forcibly bend, twist or turn the nylon tube.
    5. Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 3 fuel tubes from the fuel tank.



34. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal

  1. Set SST on the retainer.

    SST
    09808-14030
    HINT:
    1. Securely attach the claws of SST to the protrusion of the retainer and fix SST in place.
    2. Install SST while pressing the claws of SST against the retainer (towards the center of SST).


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal

  1. Using SST, loosen the retainer.

    SST
    09808-14030
    Text in Illustration
    Land Cruiser. Urj200, 202 Grj200 Vdj200
    		Turn
    NOTICE:
    1. Do not use any tools other than those specified in this operation. Damage to the retainer or the fuel tank may result.
    2. While pressing down on SST so that the claws of SST do not slip off the protrusion of the retainer, turn the retainer counterclockwise to loosen it.
    HINT:
    The protrusion of the retainer fit in the ends of SST.

  1. Remove the retainer.

  1. Remove the retainer while holding the fuel suction tube assembly by hand.

    NOTICE:
    Be careful not to bend the arm of the fuel sender gauge.

  1. Remove the gasket from the fuel tank.



35. REMOVE FUEL TANK TO FILLER PIPE HOSE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the hose from the fuel tank.



36. REMOVE NO. 1 FUEL TANK HEAT INSULATOR


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Fuel.Fuel System (W/ Dpf).Fuel Tank Removal

  1. Remove the fuel tube clamp from the heat insulator.

  1. Using needle-nose pliers, remove the 4 clips shown in the illustration and then remove the heat insulator.