2008 Lexus IS FFACTORY OEM SERVICE PROCEDURE

Fuel Pump: Installation

  1. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Install a new fuel suction tube set gasket onto the fuel tank.
    2. Connect the fuel tube with the clip
    3. Set the fuel suction with pump and tube assembly to the fuel tank
      NOTE:
      • Make sure that the fuel sender gauge assembly arm does not bend.
      • Do not damage the fuel tube.
        • Fig 1: Locating Fuel Tube With Clip
        G05750058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the protrusion of the fuel suction with pump assembly and gauge tube assembly and the cutout of the fuel tank vent tube set plate
    5. While holding the fuel suction with pump and gauge tube assembly by hand, install the fuel tank vent tube to the fuel tank with the 8 bolts

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

      Fig 2: Locating Fuel Tank Vent Tube Set Plate Bolts
      G05750081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the fuel pump tubes
      1. Push the fuel tube joint in the plug of the fuel suction plate, and then install the fuel tank main tube and fuel tank return vent tube with the 2 tube joint clips
        NOTE:
        • Check that there are no scratches or foreign objects on the connecting parts.
        • Check that the fuel tube joint is 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 have not been pulled off.
        • Be careful not to damage any clips. If a clip is damaged, replace it.
        Fig 3: Locating Fuel Pump Tubes
        G05750082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the fuel suction tube connector
  2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  3. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  4. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER 
    1. Install the No 2 rear floor service hole cover with new butyl tape
    Fig 4: Identifying Rear Floor Service Hole Cover
    G05750054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 3 ROOM PARTITION PAD 
    1. Install the No. 3 room partition pad with the clip.
    Fig 5: Identifying Room Partition Pad With Clip
    G05287239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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.