2008 Lexus ES 350FACTORY OEM SERVICE PROCEDURE

Fuel Pump: Installation

  1. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE 
    1. Install a new gasket to the fuel suction tube.
    2. Install the fuel suction tube.
      NOTE:
      • Do not damage the fuel pump filter.
      • Be careful that the arm of the sender gauge does not bend.
        Fig 1: Identifying Fuel Suction Tube
        G04975037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL TANK VENT TUBE SET PLATE 
    1. Align the mark of the set plate with the fuel suction tube.
    2. Install the set plate with the 8 bolts.

      Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf) 

      Fig 2: Locating Set Plate Bolts
      G04974947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY 
    1. Install the fuel pump tube with the tube joint clip.
      NOTE:
      • Check that there are no scratches or foreign objects on the connecting part.
      • Check that the fuel tube joint is inserted securely.
      • Check that the tube joint clip is correctly located on the collar of the fuel tube joint.
      • After installing the tube joint clip, check that the fuel tube joint is pulled out of position.
  4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See ELECTRONIC CIRCUIT INSPECTION PROCEDURE ).
  5. INSPECT FOR FUEL LEAK (See  ON-VEHICLE INSPECTION   ) 
    Fig 3: Identifying Fuel Pump Tube & Tube Joint Clip
    G04975057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Connect the fuel pump connector.
    2. Install the rear floor service hole cover with new butyl tape.
      Fig 4: Locating Rear Floor Service Hole Cover
      G04974917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL REAR SEAT CUSHION ASSEMBLY  (See INSTALLATION )
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.