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Home >> Lexus >> 2007 >> IS 350 >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel (2GR-FSE) >> Fuel Pump >> Installation

Fuel Pump: Installation

  1. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY 
    1. Apply a light coat of gasoline to 2 new O-rings, and install them to the fuel pressure regulator.
      Fig 1: Applying Light Coat Of Gasoline To O-Rings
      G04056509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel pressure regulator to the fuel relief valve.
      Fig 2: Installing Fuel Pressure Regulator To Fuel Relief Valve
      G04056510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE JET PUMP 
    1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and jet pump to the fuel relief valve assembly.
      Fig 3: Installing O-Ring And Jet Pump To Fuel Relief Valve Assembly
      G04056511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE FUEL RELIEF VALVE ASSEMBLY 
    1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and fuel relief valve assembly to the fuel filter.
      Fig 4: Installing O-Ring And Fuel Relief Valve Assembly To Fuel Filter
      G04056512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FLANGE ASSEMBLY 
    1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and flange assembly to the fuel filter.
      Fig 5: Installing O-Ring And Flange Assembly To Fuel Filter
      G04056513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FUEL PUMP 
    1. Install the fuel pump spacer to the fuel pump.
    2. Apply a light coat of gasoline to a new seal, and install it to the fuel pump.
    3. Install the fuel pump to the fuel filter.
      Fig 6: Installing Fuel Pump To Fuel Filter
      G04056514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 2 connectors and terminal.
      Fig 7: Identifying 2 Connectors And Terminal
      G04056515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL SUB-TANK NO. 1 
    1. Apply a light coat of gasoline to a new O-ring, and install the O-ring and No. 1 fuel sub-tank to the fuel filter with flange assembly.
      Fig 8: Installing O-Ring And No 1 Fuel Sub-Tank To Fuel Filter With Flange Assembly
      G04056516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the jet pump nozzle to the No. 1 fuel subtank. O-Ring
      Fig 9: Connecting Jet Pump Nozzle To No 1 Fuel Subtank. O-Ring
      G04056517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new E-ring.
      Fig 10: Identifying E-Ring
      G04056518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE SENDER GAGE ASSEMBLY 
    1. Set the fuel sender gauge to the No. 1 fuel sub-tank. Then slide the sender gauge downward to install it.
    2. Connect the fuel sender gauge connector.
  8. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Install a new gasket onto the fuel tank.
      Fig 11: Installing Gasket Onto Fuel Tank
      G04056519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the fuel hose with the clip.
    3. Set the fuel suction tube to the fuel tank.
      Fig 12: Identifying Fuel Hose With Clip
      G04056520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure that the fuel sender gauge arm does not bend.
      • Do not damage the No. 2 fuel hose.
    4. Align the protrusion of the fuel suction tube and the cutout of the fuel tank vent tube set plate.
    5. While holding the fuel suction tube by hand, install the fuel tank vent tube to the fuel tank with the 8 bolts.
      Fig 13: Installing Fuel Tank Vent Tube To Fuel Tank With 8 Bolts
      G04056521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

    6. Connect the fuel tube.
      1. Push the fuel tube joint in the plug of the fuel suction plate, then install the 2 tube joint clips.
        Fig 14: Pushing Fuel Tube Joint In Plug Of Fuel Suction Plate
        G04056522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that there are no scratches or foreign objects on the connecting parts.
      • Check that the fuel tube joint is inserted securely.
      • Check that the tube joint clips are on the collars of the fuel tube joints.
      • After installing the tube joint clips, check that the fuel tube joints have not been pulled off.
      • Be careful not to damage any clips. If a clip is damaged, replace it.
    7. Connect the fuel suction tube connector.
  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See  INSTALLATION  ) 
  10. CHECK FOR FUEL LEAKAGE (See  ON-VEHICLE INSPECTION   ) 
  11. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER 
    1. Install the No. 2 rear floor service hole cover with new butyl tape.
  12. INSTALL REAR SEAT CUSHION ASSEMBLY (See  INSTALLATION  ) 
  13. PERFORM INITIALIZATION 
    1. Perform initialization (See INITIALIZATION ).
      Fig 15: Identifying Fuel Suction Tube Connector
      G04056523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.

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