Lexus IS250 IS220d GSE20 ALE20 2AD-FHV FUEL

INSTALL NO. 2 FUEL TANK PROTECTOR

INSTALL FUEL TANK CUSHION

INSTALL FUEL TANK TO FILLER PIPE HOSE

INSTALL FUEL TANK RETURN TUBE SUB-ASSEMBLY

INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

INSTALL FUEL TANK VENT HOSE

INSTALL NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY

INSTALL FUEL TANK ASSEMBLY

CONNECT FUEL TANK TO FILLER PIPE HOSE

CONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY

CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

CONNECT FUEL TUBE

CONNECT PARKING BRAKE CABLE ASSEMBLY

INSTALL REAR SUSPENSION MEMBER BRACE LH

INSTALL REAR SUSPENSION MEMBER BRACE RH

INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE

INSTALL NO. 1 FRONT FLOOR HEAT INSULATOR

INSTALL AIR GUIDE PLATE OUTSIDE RH

INSTALL FRONT EXHAUST PIPE ASSEMBLY

INSTALL AIR FUEL RATIO SENSOR

INSTALL FRONT CENTER FLOOR BRACE

INSTALL REAR SUSPENSION MEMBER BRACE LOWER LH

INSTALL REAR SUSPENSION MEMBER BRACE LOWER RH

INSTALL REAR NO. 1 FLOOR PANEL BRACE

INSTALL FLOOR UNDER COVER

INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR

INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR

INSTALL FUEL SENDER GAUGE ASSEMBLY

INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

INSPECT PARKING BRAKE LEVER TRAVEL

ADJUST PARKING BRAKE LEVER TRAVEL

ADD FUEL

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

CHECK FOR FUEL LEAKS

CHECK FOR EXHAUST GAS LEAKAGE

INSTALL REAR FLOOR SERVICE HOLE COVER

INSTALL REAR NO. 2 FLOOR SERVICE HOLE COVER

INSTALL REAR SEAT CUSHION ASSEMBLY

PERFORM INITIALIZATION

FUEL TANK - INSTALLATION

1. INSTALL NO. 2 FUEL TANK PROTECTOR

Install the No. 2 fuel tank protector to the fuel tank assembly.

2. INSTALL FUEL TANK CUSHION

Install 11 new fuel tank cushions as shown in the illustration.

3. INSTALL FUEL TANK TO FILLER PIPE HOSE

Install the fuel tank to filler pipe hose to the fuel tank with the clamp.

Tighten the hose clamp bolt.

4. INSTALL FUEL TANK RETURN TUBE SUB-ASSEMBLY

Install the 3 clamps to the fuel tank.

Install the fuel tank return tube sub-assembly with the 3 clamps.

5. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

Install the clamp to the fuel tank.

Install the fuel tank main tube sub-assembly with the clamp.

6. INSTALL FUEL TANK VENT HOSE

Install the fuel tank vent hose with the clip.

7. INSTALL NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY

Install a new gasket to the No. 1 fuel tank breather tube sub-assembly.

Install the No. 1 fuel tank breather tube sub-assembly with the 4 bolts.

Torque:
1.5 N*m{ 15 kgf*cm, 13 in.*lbf}

8. INSTALL FUEL TANK ASSEMBLY

Set the fuel tank assembly onto the transmission jack.

Raise the transmission jack so that the fuel tank breather hose can be connected. Connect the hose.

NOTICE:

Slowly raise the jack to prevent the fuel tank assembly from dropping.

Install the fuel tank assembly with the fuel tank band and 4 bolts.

Torque:
39 N*m{ 398 kgf*cm, 29 ft.*lbf}

9. CONNECT FUEL TANK TO FILLER PIPE HOSE

Connect the fuel tank to filler pipe hose with the clamp.

10. CONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY

Connect the fuel tube clamp.

Connect the 2 fuel tubes to the fuel sedimenter assembly.

11. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

Connect the fuel tube to the fuel filter.

Connect the 3 fuel tubes to the fuel route switching valve.

12. CONNECT FUEL TUBE

Connect the fuel tank main tube.

Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.

NOTICE:

Check for damage or foreign objects on the parts that are to be connected.

After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

Connect the fuel tank return vent tube.

Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.

NOTICE:

Check for damage or foreign objects on the parts that are to be connected.

After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

13. CONNECT PARKING BRAKE CABLE ASSEMBLY

Connect the 4 clamps.

Connect the 2 parking brake cables with the 4 bolts.

Torque:
bolt A:
6.0 N*m{ 61 kgf*cm, 53 in.*lbf}
bolt B:
19 N*m{ 194 kgf*cm, 14 ft.*lbf}

14. INSTALL REAR SUSPENSION MEMBER BRACE LH

Install the rear suspension member brace LH with the 2 bolts.

Torque:
50 N*m{ 510 kgf*cm, 37 ft.*lbf}

15. INSTALL REAR SUSPENSION MEMBER BRACE RH

HINT:

Installation procedure of the RH side is the same as that of the LH side.

16. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

HINT:

17. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE

Stabilize the propeller shaft and differential.

Turn the propeller shaft several times by hand to stabilize the center support bearing.

Check both the No. 2 and No. 3 joint angles.

Using SST, measure the installation angle of the intermediate shaft and propeller shaft.

SST
09370-50010

HINT:

The SST should be set directly on the bottom of the shaft.

Using SST, measure the installation angle of the differential.

Fuel Tank - Installation. 2AD-FHV FUEL. Lexus IS250 IS220d GSE20 ALE20

SST
09370-50010

HINT:

Measure the installation angle by placing the SST in the positions shown in the illustration.

Calculate the No. 2 joint angle.

No. 2 joint angle:
A - B = -0°49' to -1°49'

A:
Intermediate shaft installation angle

B:
Propeller shaft installation angle

Calculate the No. 3 joint angle.

No. 3 joint angle:
B - C = 0°70' to 2°10'

B:
Propeller shaft installation angle

C:
Differential installation angle

HINT:

If the measured angle is not within the specified range, adjust it with the center support bearing washers.

Adjust the No. 2 joint angle.

Select the center support bearing washers for adjustment.

Adjustment washer
thickness mm (in.)
2 (0.0787)
4.5 (0.1772)
6.5 (0.2559)
9.0 (0.3543)
11.0 (0.4331)

NOTICE:

The 2 washers should be the same thickness.

18. INSTALL NO. 1 FRONT FLOOR HEAT INSULATOR

Install the front No. 1 floor heat insulator with the 4 nuts.

Torque:
5.4 N*m{ 55 kgf*cm, 48 in.*lbf}

19. INSTALL AIR GUIDE PLATE OUTSIDE RH

Install the outside air guide plate RH with the 4 nuts.

Torque:
5.4 N*m{ 55 kgf*cm, 48 in.*lbf}

20. INSTALL FRONT EXHAUST PIPE ASSEMBLY

HINT:

21. INSTALL AIR FUEL RATIO SENSOR

Before installing the air fuel ratio sensor, twist the sensor wire counterclockwise 4 turns.

Using SST, install the air fuel ratio sensor to the front exhaust pipe.

SST
09224-00010

Torque:
44 N*m{ 449 kgf*cm, 33 ft.*lbf}

22. INSTALL FRONT CENTER FLOOR BRACE

Install the front center floor brace with the 4 bolts.

Torque:
7.4 N*m{ 75 kgf*cm, 65 in.*lbf}

23. INSTALL REAR SUSPENSION MEMBER BRACE LOWER LH

Install the suspension member brace lower LH with the 4 bolts.

Torque:
19 N*m{ 195 kgf*cm, 14 ft.*lbf}

24. INSTALL REAR SUSPENSION MEMBER BRACE LOWER RH

Install the suspension member brace lower RH with the 4 bolts.

Torque:
19 N*m{ 195 kgf*cm, 14 ft.*lbf}

25. INSTALL REAR NO. 1 FLOOR PANEL BRACE

Install the rear No. 1 floor panel brace with the 4 bolts.

Torque:
19 N*m{ 195 kgf*cm, 14 ft.*lbf}

26. INSTALL FLOOR UNDER COVER

Install the No. 1 floor under cover and No. 2 floor under cover.

27. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR

Install the No. 2 differential support protector to the rear suspension member brace with the 2 nuts.

Torque:
5.4 N*m{ 55 kgf*cm, 48 in.*lbf}

28. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR

HINT:

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

29. INSTALL FUEL SENDER GAUGE ASSEMBLY

Install the fuel sender gauge to the fuel tank with the 5 bolts.

Torque:
1.5 N*m{ 15 kgf*cm, 13 in.*lbf}

Connect the fuel sender gauge connector.

30. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

Install a new gasket onto the fuel tank.

Connect the fuel hose with the clip.

Set the fuel suction tube to the fuel tank.

NOTICE:

Make sure that the fuel sender gauge arm does not bend.

Do not damage the No. 2 fuel hose.

Align the protrusion of the fuel suction tube and the cutout of the fuel tank vent tube set plate.

While holding the fuel suction tube by hand, install the fuel tank vent tube to the fuel tank with the 8 bolts.

Torque:
6.0 N*m{ 61 kgf*cm, 53 in.*lbf}

Connect the fuel tube.

Push the fuel tube joint in the plug of the fuel suction plate, then install the 2 tube joint clips.

NOTICE:

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.

Connect the fuel suction tube connector.

31. INSPECT PARKING BRAKE LEVER TRAVEL

Pull firmly on the parking brake lever.

Release the parking brake lock, and return the parking brake lever to its off position.

Slowly pull the parking brake lever all the way up, and count the number of clicks.

Parking brake lever travel:
4 to 6 notches at 200 N (20 kgf, 45 lbf)

32. ADJUST PARKING BRAKE LEVER TRAVEL

Depress the parking brake lever. Hold the No. 1 wire adjusting nut using a wrench and loosen the lock nut.

Release the parking brake lever.

Turn the No. 1 wire adjusting nut until the parking brake lever travel meets the above specification.

Hold the No. 1 wire adjusting nut using a wrench or equivalent tool and tighten the lock nut.

Torque:
6.0 N*m{ 61 kgf*cm, 53 in.*lbf}

Count the number of clicks after depressing and releasing the parking brake lever 3 or 4 times.

Check whether the parking brake drags or not.

When operating the parking brake lever, check that the parking brake indicator light comes on.

33. ADD FUEL

34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque:
5.4 N*m{ 55 kgf*cm, 48 in.*lbf}

35. CHECK FOR FUEL LEAKS

PERFORM ACTIVE TEST

Connect the intelligent tester to the DLC3.

Turn the engine switch ON (IG).

Turn the intelligent tester ON.

Enter the following menus: Powertrain / ENGINE / Active Test.

Perform the Active Test.

Intelligent Tester Display	Test Details	Control Range	Diagnostic Notes
Test the Fuel Leak	Pressurize common rail internal fuel pressure, and check for fuel leaks	Stop/Start	Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2,000 rpm when "Start" is selected Above conditions to be maintained while "Start" is selected

36. CHECK FOR EXHAUST GAS LEAKAGE

37. INSTALL REAR FLOOR SERVICE HOLE COVER