2008 Lexus IS FFACTORY OEM SERVICE PROCEDURE

Fuel Tank: Installation

  1. INSTALL NO. 1 FUEL TANK PROTECTOR 
    1. Install the No 1 fuel tank protector to the fuel tank assembly
    Fig 1: Identifying Fuel Tank Protector
    G05750146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL TANK CUSHION 
    1. Install 11 new fuel tank cushions as shown in the illustration.
    Fig 2: Identifying Fuel Tank Cushions
    G05750145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL TANK VENT HOSE 
    1. Install the fuel tank vent hose with the clip.
    Fig 3: Locating Fuel Tank Vent Hose Clip
    G05750144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL TANK TO FILLER PIPE HOSE 
    1. Install the fuel tank to filler pipe hose to the fuel tank assembly with the clamp
    Fig 4: Locating Fuel Tank To Filler Pipe Hose Clamp Bolt
    G05750143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL TUBE SUB-ASSEMBLY 
    1. Install the 2 tank bracket retainer sub-assemblies.
      Fig 5: Locating Tank Bracket Retainer Sub-Assemblies
      G05750151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the edge protector with the 2 clamps.
      Fig 6: Identifying Edge Protector Clamps
      G05750141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a fuel tank main tube and fuel tank return vent tube with the clamp.
      4. Fig 7: Identifying Fuel Tank Main Tube And Fuel Tank Return Vent Tube
      G05750140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Install a new gasket to the No 1 fuel tank breather tube sub-assembly.
    2. Install the No. 1 fuel tank breather tube sub-assembly with the 4 bolts.

      Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) 

      Fig 8: Locating Fuel Tank Breather Tube Bolts
      G05750139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL TANK ASSEMBLY 
    1. Set the fuel tank assembly onto an engine lifter
    2. Raise the engine lifter so that the No 1 fuel tank breather tube sub-assembly can be connected Connect the hose.
      NOTE: Slowly raise the lifter so as to not drop the fuel tank assembly.
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.

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