2008 Lexus IS FFACTORY OEM SERVICE PROCEDURE

Fuel Tank: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 
    1. Discharge fuel system pressure (See FUEL SYSTEM .)
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  3. REMOVE REAR SEAT CUSHION ASSEMBLY  (See REMOVAL )
  4. REMOVE NO. 3 ROOM PARTITION PAD  (See REMOVAL )
  5. REMOVE NO. 2 REAR FLOOR SERVICE HOLE COVER  (See REMOVAL )
  6. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY  (See REMOVAL )
  7. DRAIN FUEL 
  8. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the rear floor service hole cover.
    Fig 1: Identifying Rear Floor Service Hole Cover
    G05750128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL SENDER GAUGE 
    1. Disconnect the fuel sender gauge connector
      Fig 2: Locating Fuel Sender Gauge Connector
      G05750129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts and fuel sender gauge from the fuel tank.
      NOTE: Be careful not to bend the arm of the fuel sender gauge.
      3. Fig 3: Locating Fuel Sender Gauge Bolts
      G05303285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR  (See REMOVAL )
  11. REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR 

    HINT:

    Use the same procedure as for the No 2 differential support protector

  12. REMOVE NO. 2 FLOOR UNDER COVER  (See REMOVAL )
  13. REMOVE NO. 1 FLOOR UNDER COVER  (See REMOVAL )
  14. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    HINT.

    See REMOVAL .

  15. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY 

    HINT.

    See REMOVAL .

  16. REMOVE REAR SUSPENSION REAR LOWER MEMBER BRACE LH  (See REMOVAL )
  17. REMOVE REAR SUSPENSION REAR LOWER MEMBER BRACE RH  (See REMOVAL )
  18. DISCONNECT PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the 2 parking brake cable assemblies from the 4 clamps.
    2. Remove the 4 bolts and disconnect the 2 parking brake cable assemblies.
      Fig 4: Locating Parking Brake Cable Assemblies Bolts
      G05750131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt, loosen the grommet then remove No.3 fuel tank protector
    4. Remove the bolt, loosen the grommet then remove No.4 fuel tank protector
    Fig 5: Locating Fuel Tank Protector Bolt
    G05750132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank main tube (LH side)
      NOTE:
      • Remove any dirt and foreign matter on the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel pump tube.
      • If the fuel tube connector and pipe are stuck, push and pull on them to release them.
        • Fig 6: Locating Fuel Tank Main Tube (LH Side)
        G05750133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tank return vent tube
      NOTE:
      • Remove any dirt and foreign matter on the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel pump tube.
      • If the fuel tube connector and pipe are stuck, push and pull on them to release them.
        • Fig 7: Locating Fuel Tank Return Vent Tube
        G05750134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the fuel tank main tube (RH side)
      NOTE:
      • Remove any dirt and foreign matter on the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel pump tube.
      • If the fuel tube connector and pipe are stuck, push and pull on them to release them.
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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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