Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - 3UR-FE FUEL

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.

Do not use any tools to separate the pipe and connector.

Do not forcefully bend or twist the nylon tube.

Check for foreign matter on the pipe seal surface. Clean if necessary.

Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.

5. DRAIN FUEL

Connect the cable to the negative (-) battery terminal.

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected ().

Connect the intelligent tester to the DLC3.

Turn the engine switch on (IG).

NOTICE:

Do not start the engine.

Turn the intelligent tester on.

Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

CAUTION:

Do not smoke or be near an open flame when working on the fuel system.

Secure good ventilation.

Keep gasoline away from rubber or leather parts.

HINT:

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.

Disconnect the cable from the negative (-) battery terminal.

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected ().

Disconnect the fuel pump and fuel sender gauge connector.

6. PRECAUTION

NOTICE:

After turning the engine 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 ().

7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected ().

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

()

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

()

10. REMOVE REAR NO. 2 SEAT ASSEMBLY

for Face to Face Seat Type:

Remove the rear No. 2 seat assembly ().

except Face to Face Seat Type:

Remove the rear No. 2 seat assembly ().

11. REMOVE FRONT FLOOR CARPET ASSEMBLY

Turn over the floor carpet.

HINT:

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

12. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER

Remove the 2 screws and air duct.

Remove the rear floor No. 2 service hole cover.

13. DISCONNECT NO. 2 FUEL TANK BREATHER HOSE

for G.C.C. Countries:

Detach the fuel tube clamp.

Slide the clip and disconnect the No. 2 fuel tank breather hose from the pipe.

14. DISCONNECT FUEL TANK RETURN TUBE

Fuel Tank - Removal. 3UR-FE FUEL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Text in Illustration
*1	Retainer	*2	Pipe
*3	Nylon Tube	*4	Connector
*5	O-Ring	-	-
*a	except G.C.C. Countries	*b	for G.C.C. Countries
	Pull Up	-	-

Detach the fuel tube clamp.

Pull up the retainer and disconnect the fuel tank return tube.

NOTICE:

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.

Do not use any tools to separate the pipe and connector.

Do not forcefully bend or twist the nylon tube.

Check for foreign matter on the pipe seal surface. Clean if necessary.

Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.

15. DISCONNECT NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY

for G.C.C. Countries:

Detach the fuel tube clamp.

Pull up the retainer and disconnect the No. 1 fuel emission tube sub-assembly.

NOTICE:

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.

Do not use any tools to separate the pipe and connector.

Do not forcefully bend or twist the nylon tube.

Check for foreign matter on the pipe seal surface. Clean if necessary.

Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.

Text in Illustration
*1	Retainer
*2	Pipe
*3	Nylon Tube
*4	Connector
*5	O-Ring
	Pull Up

except G.C.C. Countries:

Detach the fuel tube clamp.

Pull the retainer up while pinching it on both sides by hand as shown in the illustration, and disconnect the No. 1 fuel emission tube sub-assembly.

NOTICE:

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.

Do not use any tools to separate the pipe and connector.

Do not forcefully bend or twist the nylon tube.

Check for foreign matter on the pipe seal surface. Clean if necessary.

Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.

Text in Illustration
*1	Retainer
*2	Connector
*3	O-Ring
*4	Pipe
*5	Nylon Tube
	Push
	Pull Up

16. DISCONNECT FUEL HOSE

for G.C.C. Countries:

Detach the fuel tube clamp.

Slide the clip and disconnect the fuel hose from the pipe.

17. DISCONNECT NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY

Fuel Tank - Removal. 3UR-FE FUEL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Text in Illustration
*1	Retainer	*2	Connector
*3	O-Ring	*4	Pipe
*5	Nylon Tube	-	-
*a	except G.C.C. Countries	*b	for G.C.C. Countries
	Pull Up	-	-

Detach the fuel tube clamp.

Pull up the retainer and disconnect the No. 2 fuel tank main tube sub-assembly.

NOTICE:

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.

Do not use any tools to separate the pipe and connector.

Do not forcefully bend or twist the nylon tube.

Check for foreign matter on the pipe seal surface. Clean if necessary.

Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.

18. DISCONNECT NO. 2 FUEL TANK BREATHER TUBE

except G.C.C. Countries:

Detach the fuel tube clamp.

Pull up the retainer and disconnect the No. 2 fuel tank breather tube.

NOTICE:

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.

Do not use any tools to separate the pipe and connector.

Do not forcefully bend or twist the nylon tube.

Check for foreign matter on the pipe seal surface. Clean if necessary.

Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.

Text in Illustration
*1	Retainer
*2	Connector
*3	O-Ring
*4	Pipe
*5	Nylon Tube
	Pull Up

19. DISCONNECT FUEL TANK BREATHER TUBE

Detach the fuel tube clamp.

Pull up the retainer and disconnect the fuel tank breather tube from the fuel tank to filler pipe sub-assembly.

Text in Illustration
*1	Retainer
	Pull Up

NOTICE:

Do not use any tools in this procedure.

Check for any dirt and foreign matter contamination 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.

20. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

Loosen the hose clamp and disconnect the fuel tank to filler pipe hose from the fuel tank to filler pipe sub-assembly.

21. REMOVE FUEL TANK SUB-ASSEMBLY

Place an engine lifter under the fuel tank sub-assembly.

Remove the 2 bolts, 2 clips, 2 pins and 2 fuel tank band sub-assemblies.

Slowly lower the engine lifter slightly.

22. REMOVE FUEL HOSE

for G.C.C. Countries:

Slide the clip and remove the fuel hose from the fuel suction tube sub-assembly.

23. REMOVE FUEL TANK MAIN TUBE, FUEL TANK RETURN TUBE AND NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY

Remove the 3 tube joint clips and pull out the 3 fuel tube joints.

NOTICE:

Remove any dirt and foreign matter on the fuel tube joint before performing this work.

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.

Perform this work by hand. Do not use any tools.

Do not forcibly bend, twist or turn the nylon tube.

Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.

Text in Illustration
*1	Fuel Tube Joint
*2	Tube Joint Clip
*3	O-Ring
*4	Fuel Suction Plate Sub-assembly

except G.C.C. Countries:

Detach the clamp and remove the fuel tank main tube sub-assembly.

Text in Illustration
*1	Fuel Tank Main Tube Sub-assembly
*2	Fuel Tank Return Tube Sub-assembly
*3	No. 2 Fuel Tank Main Tube Sub-assembly

Detach the clamp and remove the fuel tank return tube sub-assembly.

Detach the 2 clamps and remove the No. 2 fuel tank main tube sub-assembly.

for G.C.C. Countries:

Detach the clamp and remove the fuel tank main tube sub-assembly.

Text in Illustration
*1	Fuel Tank Main Tube Sub-assembly
*2	Fuel Tank Return Tube Sub-assembly
*3	No. 2 Fuel Tank Main Tube Sub-assembly

Detach the clamp and remove the fuel tank return tube sub-assembly.

Detach the 2 clamps and remove the No. 2 fuel tank main tube sub-assembly.

24. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

Set SST on the retainer.

SST
09808-14030

HINT:

Securely attach the claws of SST to the protrusion of the retainer and fix SST in place.

Install SST while pressing the claws of SST against the retainer (towards the center of SST).

Using SST, loosen the retainer.

SST
09808-14030

NOTICE:

Do not use any tools other than those specified in this operation. Damage to the retainer or the fuel tank may result.

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.

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

Remove the gasket from the fuel tank.

25. REMOVE FUEL TANK TO FILLER PIPE HOSE

Loosen the hose clamp and remove the fuel tank to filler pipe hose from the fuel tank sub-assembly.

26. REMOVE NO. 1 FUEL TANK HEAT INSULATOR

Remove the fuel tube clamp from the No. 1 fuel tank heat insulator.

Text in Illustration
*a	for G.C.C. Countries

Using needle-nose pliers, remove the 4 clips shown in the illustration, and then remove the No. 1 fuel tank heat insulator.