Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - 1GR-FE FUEL

INSTALL NO. 1 FUEL TANK HEAT INSULATOR

INSTALL FUEL TANK TO FILLER PIPE HOSE

INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

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

INSTALL FUEL HOSE

INSTALL FUEL TANK SUB-ASSEMBLY

CONNECT FUEL TANK TO FILLER PIPE HOSE

CONNECT FUEL TANK BREATHER TUBE

CONNECT NO. 2 FUEL TANK BREATHER TUBE

CONNECT NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY

CONNECT FUEL HOSE

CONNECT NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY

CONNECT FUEL TANK RETURN TUBE

CONNECT NO. 2 FUEL TANK BREATHER HOSE

CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

INSTALL FUEL TANK CAP ASSEMBLY

INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER

INSTALL FRONT FLOOR CARPET ASSEMBLY

INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH

INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH

INSTALL REAR NO. 2 SEAT ASSEMBLY

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

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

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

CHECK SRS WARNING LIGHT

ADD FUEL

INSPECT FOR FUEL LEAK

FUEL TANK - INSTALLATION

1. INSTALL NO. 1 FUEL TANK HEAT INSULATOR

Install the No. 1 fuel tank heat insulator with the 4 clips.

Install the fuel tube clamp to the No. 1 fuel tank heat insulator.

2. INSTALL FUEL TANK TO FILLER PIPE HOSE

Fuel Tank - Installation. 1GR-FE FUEL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the fuel tank to filler pipe hose to the fuel tank sub-assembly as shown in the illustration and tighten the hose clamp.

Text in Illustration
*1	Fuel Tank Side Mark
*2	Hose Side Mark

HINT:

Align the fuel tank side mark with the hose side mark when installing the hose.

Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.

Text in Illustration
*a	Stopper

3. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

Apply a light coat of gasoline or grease to a new gasket, and install it to the fuel tank.

Install the fuel suction with pump and gauge tube into the fuel tank.

Text in Illustration
*1	Protrusion
*2	Groove
	Front

NOTICE:

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

HINT:

Align the protrusion of the fuel suction with pump and gauge tube with the groove of the fuel tank.

Put the retainer on the fuel tank. While holding the fuel suction with pump and gauge tube, tighten the retainer one complete turn by hand.

Set SST on the retainer.

SST
09808-14030

HINT:

Hold the fuel suction tube assembly upright by hand to ensure that the fuel suction tube gasket is not moved out of position.

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

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

Using SST, tighten the retainer until the mark on the retainer is within range A on the fuel tank as shown in the illustration.

SST
09808-14030

Text in Illustration
*1	Fuel Tank Side Mark
*2	Retainer Side Mark

HINT:

Fit the tips of SST onto the ribs of the retainer.

4. INSTALL FUEL TANK MAIN TUBE, FUEL TANK RETURN TUBE AND NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY

Install the 3 fuel tank tubes with the 3 tube joint clips.

NOTICE:

Check that there are no scratches or foreign objects on the connecting parts.

Check that the fuel tube joints are inserted securely.

Check that the tube joint clips are on the collars of the fuel tube joints.

After installing the tube joint clips, check that the fuel tube joints cannot be pulled off.

Text in Illustration
*1	Fuel Tube Joint
*2	O-Ring
*3	Tube Joint Clip
*a	CORRECT
*b	INCORRECT

for G.C.C. Countries:

Attach the 2 clamps and install the No. 2 fuel tank main tube sub-assembly.

Attach the clamp and install the fuel tank return tube sub-assembly.

Attach the clamp and install the fuel tank main tube sub-assembly.

except G.C.C. Countries:

Attach the 2 clamps and install the No. 2 fuel tank main tube sub-assembly.

Attach the clamp and install the fuel tank return tube sub-assembly.

Attach the clamp and install the fuel tank main tube sub-assembly.

5. INSTALL FUEL HOSE

for G.C.C. Countries:

Install the fuel hose to the fuel suction tube sub-assembly, and slide the clip to secure the hose.

6. INSTALL FUEL TANK SUB-ASSEMBLY

Set the fuel tank sub-assembly on an engine lifter and raise the fuel tank sub-assembly.

NOTICE:

Do not allow the fuel tank sub-assembly to contact the vehicle, especially the differential.

Raise the engine lifter.

Install the 2 fuel tank band sub-assemblies with the 2 pins and 2 clips.

Connect the 2 fuel tank band sub-assemblies with the 2 bolts.

Torque:
40 N*m{ 408 kgf*cm, 30 ft.*lbf}

7. CONNECT FUEL TANK TO FILLER PIPE HOSE

Connect the fuel tank to filler pipe hose to the fuel tank to filler pipe sub-assembly as shown in the illustration and tighten the hose clamp.

Text in Illustration
*a	0 to 0.3 mm (0 to 0.0118 in.)
*b	Fuel Tank to Filler Pipe Hose Side Mark
*c	Fuel Tank Inlet Pipe Side Mark

HINT:

Install the hose so that the distance between the fuel tank inlet pipe side mark and fuel tank to filler pipe hose side mark is 0 to 0.3 mm (0 to 0.0118 in.) as shown in the illustration.

Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.

Text in Illustration
*a	Stopper

8. CONNECT FUEL TANK BREATHER TUBE

Connect the fuel tank breather tube to the fuel tank to filler pipe sub-assembly and push the retainer.

NOTICE:

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.

After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

Text in Illustration
*1	Retainer
	Push

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

9. CONNECT NO. 2 FUEL TANK BREATHER TUBE

except G.C.C. Countries:

Connect the No. 2 fuel tank breather tube and push the retainer.

NOTICE:

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.

After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

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

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

10. CONNECT NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY

Fuel Tank - Installation. 1GR-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
	Push	-	-

Connect the No. 2 fuel tank main tube sub-assembly and push the retainer.

NOTICE:

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.

After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

11. CONNECT FUEL HOSE

for G.C.C. Countries:

Connect the fuel hose to the pipe, and slide the clip to secure the hose.

Attach the fuel tube clamp.

12. CONNECT NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY

except G.C.C. Countries:

Connect the No. 1 fuel emission tube sub-assembly and push the retainer.

NOTICE:

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.

After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

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

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

for G.C.C. Countries:

Connect the No. 1 fuel emission tube sub-assembly and push the retainer.

NOTICE:

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.

After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

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

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

13. CONNECT FUEL TANK RETURN TUBE

Fuel Tank - Installation. 1GR-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
	Push	-	-

Connect the fuel tank return tube and push the retainer.

NOTICE:

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.

After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

14. CONNECT NO. 2 FUEL TANK BREATHER HOSE

for G.C.C. Countries:

Connect the No. 2 fuel tank breather hose to the pipe, and slide the clip to secure the hose.

Attach the fuel pipe clamp.

15. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

Fuel Tank - Installation. 1GR-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
	Push	-	-

Connect the fuel tank main tube sub-assembly and push the retainer.

NOTICE:

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.

After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

16. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

Install the No. 1 fuel tank protector sub-assembly with the 5 bolts.

Torque:
20 N*m{ 204 kgf*cm, 15 ft.*lbf}

17. INSTALL FUEL TANK CAP ASSEMBLY

18. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER

Connect the fuel pump and fuel sender gauge connector.

Install the rear floor No. 2 service hole cover with new butyl tape.

w/ Rear Air Conditioning System:

Install the air duct and 2 screws.

19. INSTALL FRONT FLOOR CARPET ASSEMBLY

20. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH

w/ Sliding Roof ()

w/o Sliding Roof ()

21. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH

w/ Sliding Roof ()

w/o Sliding Roof ()

22. INSTALL REAR NO. 2 SEAT ASSEMBLY

for Face to Face Seat Type ()

except Face to Face Seat Type ()

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

()

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

()

25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

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

26. CHECK SRS WARNING LIGHT

()

27. ADD FUEL

28. INSPECT FOR FUEL LEAK

Make sure that there are no fuel leaks after performing maintenance on the fuel system.

Connect the GTS to the DLC3.

Turn the ignition switch to ON and turn the GTS on.

NOTICE:

Do not start the engine.

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

Check that there are no leaks from the fuel system.

If there are fuel leaks, repair or replace parts as necessary.

Turn the ignition switch off.

Disconnect the GTS from the DLC3.