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Disassembly [09/2022 - ]: Procedure

WARNING: This page is about a different car, the 2024 Lexus IS 500, 2023 Lexus IS 500, and 2022 Lexus IS 500. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE FUEL SENDER GAUGE ASSEMBLY 

    See step  2

  2. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY (for Brush Type Motor) 
    1. Disengage the clamp to disconnect the fuel pump harness from the fuel suction plate sub-assembly.
      GTY498819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel pump harness connector.
    3. Using needle nose pliers, remove the E-ring from the fuel suction plate shaft.
      GTY517938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 E-ring
    4. Remove the fuel suction plate sub-assembly and spring from the No. 1 fuel sub-tank.
  3. REMOVE FUEL FILTER (for Brush Type Motor) 
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the 2 claws, and remove the fuel filter and fuel pump with filter assembly from the No. 1 fuel sub-tank.
      GTY507349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

      Do not damage the No. 1 fuel sub-tank or fuel filter.

  4. REMOVE JET PUMP (for Brush Type Motor) 
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the claw and remove the fuel tube.
      GTY512734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    2. Using a screwdriver with its tip wrapped with protective tape, remove the jet pump from the No. 1 fuel sub-tank.
      GTY497482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    3. Remove the O-ring from the jet pump.
      GTY502489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
      *a Jet Pump
  5. REMOVE NO. 1 FUEL SUCTION SUPPORT (for Brush Type Motor) 
    GTY508637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *1 No. 1 Fuel Suction Support
    *a Protective Tape
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the 2 claws and remove the No. 1 fuel suction support from the fuel filter.
  6. REMOVE FUEL PUMP WITH FILTER ASSEMBLY (for Brush Type Motor) 
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the 3 claws, and remove the fuel pump with filter assembly from the fuel filter.
      GTY509327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Filter
      *b Suction Filter
      *c Protective Tape
      NOTE:
      • Do not damage the fuel filter.
      • Do not remove the suction filter.
      • Do not use either the fuel pump with filter assembly or the suction filter if the suction filter is removed from the fuel pump with filter assembly.

        Refer to PRECAUTION [09/2022 - ]

    2. Remove the O-ring and the fuel pump spacer from the fuel pump with filter assembly.
      GTY1084293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
      *2 Fuel Pump Spacer
      *a 5.0 mm (0.197 in.)
      NOTE:

      Be careful not to damage the sealing surface.

      HINT: 

      If the O-ring still remains in the fuel filter, remove it using a wire tip (1.0 mm (0.0394 in.) diameter) that is formed as shown in the illustration.

  7. REMOVE FUEL MAIN VALVE ASSEMBLY (for Brush Type Motor) 
    1. Disengage the 2 claws to remove the No. 2 fuel suction support from the fuel filter.
      GTY1084373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver with its tip wrapped with protective tape, remove the fuel main valve assembly from the fuel filter.
      GTY1084326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

      Slowly pull out the fuel main valve assembly because the O-rings are firmly installed between the fuel main valve assembly and fuel filter.

    3. Remove the 2 O-rings from the fuel main valve assembly.
      GTY470974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
  8. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY (for Brushless Type Motor) 
    1. Disconnect the 2 fuel pump harness connectors.
      GTY660227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp to disconnect the fuel pump harness from the fuel suction plate sub-assembly.
    3. Using needle nose pliers, remove the E-ring from the fuel suction plate shaft.
      GTY660226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the 2 claws and disconnect the jet pump nozzle from the No. 1 fuel sub-tank.
      GTY660225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a screwdriver with its tip wrapped with protective tape, remove the jet pump from the No. 1 fuel sub-tank.
      GTY783858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:
      • Do not damage the No. 1 fuel sub-tank, fuel filter or jet pump.
      • Pull out the jet pump carefully because the O-ring is firmly installed between the jet pump and No. 1 fuel sub-tank.
    6. Disengage the 2 claws and remove the fuel filter from the No. 1 fuel sub-tank.
      GTY660224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the spring from the fuel suction plate shaft.
    8. Remove the O-ring from the No. 1 fuel sub-tank.
      GTY660232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 1 FUEL SUCTION SUPPORT (for Brushless Type Motor) 
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the 2 claws and remove the No. 1 fuel suction support from the fuel filter.
      GTY787536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
  10. REMOVE FUEL PUMP FILTER (for Brushless Type Motor) 
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the 3 claws, and remove the fuel pump filter from the fuel filter.
      GTY785160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Filter
      *b Fuel Pump Filter
      *c Protective Tape
    2. Disengage the claw to disconnect the fuel pump harness from the fuel pump filter.
      GTY628768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL PUMP (for Brushless Type Motor) 
    1. Remove the fuel pump from the fuel filter.
      GTY628775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel pump harness connector to remove the fuel pump harness from the fuel pump.
      GTY628776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring and fuel pump spacer from the fuel pump.
      GTY782938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
      *2 Fuel Pump Spacer
      *a 5.0 mm (0.197 in.)
      NOTE:

      Be careful not to damage the sealing surface.

      HINT: 

      If the O-ring still remains in the fuel filter, remove it using a wire tip (1 mm (0.0394 in.) diameter) that is formed as shown in the illustration.

  12. REMOVE FUEL MAIN VALVE ASSEMBLY (for Brushless Type Motor) 
    1. Remove the clip from the fuel filter.
      GTY804760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver with its tip wrapped with protective tape, remove the fuel main valve assembly from the fuel filter.
      NOTE:
      • Pull out the fuel main valve assembly carefully because the O-rings are firmly installed between the fuel main valve assembly and fuel filter.
      • Do not damage the fuel filter.
      GTY786103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    3. Remove the 2 O-rings from the fuel main valve assembly.
      GTY652718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
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