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Home >> Lexus >> 2006 >> IS 250 RWD, Automatic >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel (4GR-FSE) >> Fuel Tank >> Removal

Fuel Tank: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    See PRECAUTION  .

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. REMOVE REAR SEAT CUSHION ASSEMBLY (See  REMOVAL  ) 
  4. REMOVE NO. 2 REAR FLOOR SERVICE HOLE COVER (See Step 4 in  REMOVAL   ) 
  5. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY (See Step 5 in  REMOVAL   ) 
  6. DRAIN FUEL 
  7. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the rear floor service hole cover.
    Fig 1: Removing Rear Floor Service Hole Cover
    G04044644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL SENDER GAUGE ASSEMBLY 
    1. Disconnect the fuel sender gauge connector.
      Fig 2: Disconnecting Fuel Sender Gauge Connector
      G04044645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts and fuel sender gauge.
    3. Remove the fuel sender gauge from the fuel tank.
      Fig 3: Removing Fuel Sender Gauge
      G04044646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to bend the arm of the fuel sender gauge.
  9. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    HINT:

    See Step 5 in REMOVAL .

  10. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY 

    HINT:

    See Step 4 in REMOVAL .

  11. REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR (See Step 3 in  REMOVAL  ) 
  12. REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR 

    HINT:

    Removal procedure of the No. 1 differential support protector is the same as that of the No. 2 differential support protector.

  13. REMOVE REAR FLOOR SIDE MEMBER COVER LH 
  14. REMOVE REAR FLOOR SIDE MEMBER COVER RH 
  15. REMOVE REAR SUSPENSION MEMBER BRACE LH 
    1. Remove the 4 bolts and suspension member brace lower LH.
    Fig 4: Removing Suspension Member Brace Lower LH
    G04044647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE REAR SUSPENSION MEMBER BRACE RH 
    1. Remove the 4 bolts and suspension member brace lower RH.
    Fig 5: Removing Suspension Member Brace Lower RH
    G04044648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the 2 parking brake cables from the 4 clamps.
    2. Remove the 4 bolts and disconnect the 2 parking brake cables.
    Fig 6: Disconnecting Parking Brake Cables
    G04044649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank return vent tube.
      Fig 7: Disconnecting Fuel Tank Return Vent Tube
      G04044650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any dirt and foreign objects on the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign objects 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.
    2. Disconnect the fuel tank main tube.
      Fig 8: Disconnecting Fuel Tank Main Tube
      G04044651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any dirt and foreign objects on the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign objects 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.
  19. DISCONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.
    Fig 9: Disconnecting Fuel Tank To Filler Pipe Hose
    G04044652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT NO. 3 FUEL HOSE SUB-ASSEMBLY 
    1. Disconnect the fuel hose clamp.
    2. Remove the clip and disconnect the No. 3 fuel hose sub-assembly.
    Fig 10: Disconnecting No 3 Fuel Hose Sub-Assembly
    G04044653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tube clamp.
    2. Disconnect the fuel tank to canister tube sub-assembly.
      Fig 11: Disconnecting Fuel Tank To Canister Tube Sub-Assembly
      G04044654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any dirt and foreign objects on the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign objects 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.
  22. REMOVE FUEL TANK ASSEMBLY 
    1. Place a engine lifter under the fuel tank assembly.
    2. Remove the 4 bolts, fuel tank bands and fuel tank assembly.
    Fig 12: Removing Fuel Tank Bands & Fuel Tank Assembly
    G04044655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Remove the 4 bolts, No. 1 fuel tank breather tube sub-assembly and gasket.
    Fig 13: Removing No. 1 Fuel Tank Breather Tube Sub-Assembly
    G04044656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FUEL TUBE SUB-ASSEMBLY 
    1. Disconnect the clamp and remove the fuel tank main tube and fuel tank return vent tube.
      Fig 14: Removing Fuel Tank Main Tube & Fuel Tank Return Vent Tube
      G04044657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 clamps and remove the edge protector.
    Fig 15: Removing Edge Protector
    G04044658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE FUEL TANK TO FILLER PIPE HOSE 
    1. Loosen the hose clamp bolt and remove the fuel tank to filler pipe hose from the fuel tank.
    Fig 16: Removing Fuel Tank To Filler Pipe Hose From Fuel Tank
    G04044659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE FUEL TANK VENT HOSE 
    1. Push the fuel tank vent hose deep into the fuel tank to release the lock pin.
    2. Pinch portion A.
    3. Pull out the fuel tank vent hose.
    4. Remove the fuel vapor containment valve from the fuel tank.
    Fig 17: Removing Fuel Tank Vent Hose
    G04044660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE FUEL TANK CUSHION 
    1. Remove the 11 fuel tank cushions.
    Fig 18: Removing Fuel Tank Cushions
    G04044661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE NO. 2 FUEL TANK PROTECTOR 
    1. Remove the No. 2 fuel tank protector from the fuel tank assembly.
    Fig 19: Removing No. 2 Fuel Tank Protector From Fuel Tank Assembly
    G04044662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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