◄ IMPORTANT UPDATE ►
The attached Dealer Letter has been updated. Refer to the details below.
DATE
October 5, 2020

TOPIC
A watermark has been added to the Technical Instructions to indicate that Limited
Service Campaign H0J has expired as of October 5, 2020.

Please review this notification with your staff to assure that all relevant personnel have been briefed regarding
this subject.
Thank you for your cooperation.

© 2020 Toyota Motor Sales, USA

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TECHNICAL INSTRUCTIONS

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SPECIAL SERVICE CAMPAIGN H0J

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FUEL TANK REPLACEMENT

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CERTAIN 2007-2014 MODEL YEAR FJ CRUISER

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Guam & Saipan Only

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The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing
this repair are required to successfully complete the most current version of the E-Learning course “Safety Recall
and Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly; technicians
performing this SSC repair are required to currently hold at least one of the following certification levels:

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Certified Technician (Any Specialty)
Expert Technician (Any Specialty)
Master Technician
Master Diagnostic Technician

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It is the dealership’s responsibility to select technicians with the above certification level or greater to perform
this Special Service Campaign repair. Carefully review your resources, the technician skill level, and ability
before assigning technicians to this repair. It is important to consider technician days off and vacation schedules
to ensure there are properly trained technicians available to perform this repair at all times.

I.

OPERATION FLOW CHART

The flow chart is for reference only. DO NOT use it in place of the full technical instructions. Follow ALL
steps as outlined in the full technical instructions to confirm the campaign is completed correctly.
No further action required.
Release vehicle

Not Involved

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Verify Vehicle Eligibility
1. Check the TIS Vehicle Inquiry
System.

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Invoved

5,

Replace the fuel tank.

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Campaign complete.

II. BACKGROUND

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Due to extreme ultraviolet (UV) and high humidity conditions unique to Guam and Saipan, material of the inlet
portion of the fuel tank may degrade, resulting in surface cracks. These cracks may grow over time due to
stress and high temperatures. As a result, a Malfunction Indicator Lamp (MIL) may illuminate and fuel seepage
may occur around the fuel tank inlet.

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III. IDENTIFICATION OF AFFECTED VEHICLES
A. COVERED VIN RANGE

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Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Special Service Campaign,
and that the campaign has not already been completed prior to dealer shipment or by another dealer.
TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or
were completed by another dealer.

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IV. PREPARATION
Part Description
Fuel Tank
Fuel Pump Retainer
Fuel Suction Tube Gasket
Fuel Tank Cushion No. 1
Fuel Tank Cushion No. 2
Fuel Tank Cushion No. 3
Fuel Tank Cushion No. 4

B. MATERIALS

Techstream
•
Standard Hand Tools

SST
Part Number
09808-14030-KIT

Plastic Bags

• Transmission Jack

Torque Wrench

Part Name
Fuel Sender Lock Nut Wrench Set*

Quantity
1

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• Protective Tape
C. TOOLS & EQUIPMENT

Quantity
1
1
1
1
1
1
1

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Part Number
77001-3D551
77144-35010
77169-30050
77651-35070
77652-35060
77653-35050
77654-35010

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A. PARTS

Bolt

1

09808-01030

Plate

1

09808-01040

Claw

1

09808-01050

Bolt and Washer set

1

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09808-01020

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*The kit above contains the following:
Part Number
Part Name
Quantity
09808-01010
Handle
1

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V. SAFETY PRECAUTIONS
CRITICAL INFORMATION – READ THOROUGHLY

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These cautions should be observed when performing this campaign. Failure to follow these
cautions could result in damaged parts or inadequate repair quality.
1. VENTILATION
a) Preform this repair in a well-ventilated area.
b) DO NOT have any electrical devises operating in the
area that could generate a spark.
c) Any spilled fuel should be cleaned up immediately
and
clean up material should be disposed of in
accordance
with local and state regulations.

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2. DIFFUSE FUEL VAPOR
a) Periodically use compressed air to clear the area of
fuel vapor build up.

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3. PERSONAL PROTECTION
a) Gasoline emits vapors that could cause physical
illness.
Use an appropriately rated gas mask when needed.
b) Wear protective eye wear when performing this
repair.
FIRE PREVENTION
a) Ensure that there are working fire extinguishers
nearby.
b) Ensure that there are no open flames in the area.
c) Be aware of static electricity.

5. DO NOT ALLOW FUEL TO COME INTO CONTACT
WITH INTERIOR COMPONENTS

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VI. COMPONENTS

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VII. VEHICLE PREPARATION
This campaign only covers the replacement of the fuel tank.
No other components in the engine management system are covered under this campaign.

OPEN ALL 4 WINDOWS
a) Lower all 4 windows to prevent fuel vapor
from condensing in the vehicle.

2.

CHECK FOR DTC’S
a) Using Techstream, perform a health check to

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3.

CHECK FUEL LEVEL
a) Check and record fuel level to ensure
correct sender operation after tank
replacement.
NOTE: The fuel tank will need to be drained
completely.
b) Drain fuel tank.
NOTE: Refer to the APPENDIX for
information regarding draining the
fuel tank.
Dispose of any fuel in accordance
with local regulations.

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confirm if there are any DTCs present in the
system (current, history or pending).
b) Record and clear any codes.

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DISCHARGE THE FUEL SYSTEM
a) Refer to TIS for instructions to discharge the fuel system:
Vehicles Without Secondary Air
Injection System

2007 MY

2008 MY

Vehicles With Secondary Air
Injection System

2013 MY

2014 MY

2009 MY

2010 MY

2011 MY

2012 MY

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4.

VIII. REMOVE THE FUEL TANK

POWER DOWN VEHICLE
a) Disconnect the negative battery cable.

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a) Remove the fuel filler cap to relieve
pressure in the tank.
b) Remove the fuel service cover.

2.

REMOVE THE SCUFF PLATES
a) Disengage the 14 claws and remove the
front scuff plate.

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