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Home >> Lexus >> 2024 >> RX 500h >> Repair and Diagnosis >> External Pages >> Different car >> Section 42 (Fuel System - Service Information (2 Of 2)) >> FUEL PUMP (for PHEV Model) >> Removal [08/2023 - ] >> Procedure

Removal [08/2023 - ]: Procedure

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  1. PRECAUTION 
    NOTE:

    After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

    Refer to BEFORE DISCONNECTING BATTERY [10/2022 - ]
  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [08/2023 - ]

  3. REMOVE BATTERY SERVICE COVER PLATE 

    Refer to PROCEDURE - Step 2

  4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 3

  5. REMOVE REAR SEAT ASSEMBLY 

    Refer to REMOVAL [08/2023 - ]

  6. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 21

  7. REMOVE NO. 3 BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 22

  8. REMOVE REAR DOOR SCUFF PLATE RH 
    1. Use the same procedure as for the LH side.
  9. REMOVE NO. 2 BATTERY SERVICE COVER BOARD 
    1. Use the same procedure as for the LH side.
  10. REMOVE BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 7

  11. REMOVE FOLD SEAT CONTROL ECU (for Power Seat) 

    Refer to REMOVAL [08/2023 - ]

  12. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9

  13. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. GTY1204652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Turn back the No. 2 floor mat.
      2. Using a clip remover with its tip wrapped with protective tape, remove the rear floor service hole cover and butyl tape.
      3. Disconnect the fuel tank pressure sensor (vapor pressure sensor) connector.
      4. Disconnect the 2 fuel suction tube with pump and gauge assembly connectors.
  14. REMOVE FUEL TANK COVER 
    1. GTY1074992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fold Line - -
      1. Remove the fuel tank cover from the fuel tank assembly.
        NOTE:

        Do not damage the fuel tank pressure sensor (vapor pressure sensor) and the connector.

        HINT: 

        Because the fuel tank cover is larger than the service hole, remove it while bending it.

  15. REMOVE FUEL TANK PRESSURE SENSOR (VAPOR PRESSURE SENSOR) 
    Refer to PROCEDURE - Step 3
  16. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. GTY1075542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disconnect the fuel tank vent hose sub-assembly from the fuel suction tube with pump and gauge assembly.

        Refer to PRECAUTION [08/2023 - ]

  17. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. GTY1203654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Tube Joint Clip *2 Fuel Tank Main Tube Sub-assembly
      *3 Fuel Suction Plate Sub-assembly - -
      *a Nylon Tube *b Fuel Tube Joint
      *c O-ring - -
      Pull off Pull off
      1. Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.
        NOTE:
        • Remove any foreign matter on the fuel tube joint before performing this work.
        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
        • Be sure to disconnect the fuel tube joint by hand.
        • Do not bend, twist, pinch or kink the nylon tube.
        • Cover the disconnected fuel tube joint with a plastic bag to prevent damage and contamination.
        • If the fuel tube joint and fuel suction plate sub-assembly are stuck, push and pull to release them.
  18. REMOVE NO. 1 FUEL TUBE CLAMP 
    1. GTY1075948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FUEL PUMP GAUGE RETAINER 
    1. GTY1074941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Plate) *b SST (Bolt)
      *c SST (Claw) *d SST (Handle)
      *e Insertion Point - -
      1. Remove the fuel pump gauge retainer.

        1. Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.

        • SST: 09808-01071 
        • SST: 09808-14031 
          1. 09808-01030
          2. 09808-01090

        HINT: 

        Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.

        2. While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).

        3. Install SST (handle) to SST (plate).

        • SST: 09808-14031 
          1. 09808-01010

        4. Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing down on SST, rotate SST (handle) slowly to loosen the fuel pump gauge retainer.

        NOTE:
        • Do not use any tools other than specified as this may result in damage to the fuel pump gauge retainer or fuel tank assembly.
        • Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
        • Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.
        • Do not spin SST too fast or use an impact wrench as this may result in damage to components.
        • If SST comes off of the fuel pump gauge retainer, loosen SST (bolt) and reinstall SST.

        5. While pressing down on the fuel suction tube with pump and gauge assembly, remove the fuel pump gauge retainer.

  20. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 
    1. GTY1254286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Type A *B for Type B
      1. Remove the fuel suction tube with pump and gauge assembly from the fuel tank assembly.
        NOTE:

        Be careful not to bend the arm of the fuel sender gauge assembly.

  21. REMOVE FUEL SUCTION TUBE SET GASKET 
    1. GTY1074948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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