Fuel Tank - Removal

Lexus IS250 IS220d GSE20 ALE20 4GR-FSE FUEL

FUEL TANK - REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
  • HINT:
  • .
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE REAR SEAT CUSHION ASSEMBLY
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Detach the 2 front hooks of the seat cushion from the vehicle body.

  • NOTICE:
  • Follow the instructions below carefully as the cushion frame deforms easily.

Choose a hook to detach first. Place your hands near the hook as shown in the illustration. Then lift the seat cushion to detach the hook.

Repeat for the other hook.

Detach the 2 rear hooks of the seat cushion from the seatback.

Remove the seat cushion.

4. REMOVE NO.2 REAR FLOOR SERVICE HOLE COVER
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Remove the No. 2 rear floor service hole cover and disconnect the fuel suction tube connector.

5. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Disconnect the connector from the fuel suction with pump and gauge assembly.

Disconnect fuel pump tube.

  • NOTICE:
  • Before beginning this procedure, check for foreign matter on the joint clips. Clean if necessary.

Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Remove the 2 tube joint clips, fuel tank main tube and fuel tank return vent tube.

  • NOTICE:
Keep the O-ring free of foreign matter, as it becomes contaminated easily.
Do not use any tools in this procedure.
Do not forcefully bend or twist the tube.
Put the tube in a plastic bag to prevent damage and contamination.
If the fuel suction plate and tube are stuck together, pinch the tube and turn it carefully to disconnect it.
Be careful not to damage any clips. If a clip is damaged, replace it.
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Remove the 8 bolts and the fuel tank vent tube set plate.

  • HINT:
  • While holding the fuel suction tube by hand, remove the fuel tank vent tube set plate.
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Disconnect the fuel tube.

Remove the fuel suction tube from the fuel tank.

  • HINT:
Make sure that the fuel sender gauge arm does not bend.
Do not damage the No. 2 fuel hose.
6. DRAIN FUEL
7. REMOVE REAR FLOOR SERVICE HOLE COVER
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Remove the rear floor service hole cover.

8. REMOVE FUEL SENDER GAUGE ASSEMBLY
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Disconnect the fuel sender gauge connector.

Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Remove the 5 bolts and fuel sender gauge.

Remove the fuel sender gauge from the fuel tank.

  • NOTICE:
  • Be careful not to bend the arm of the fuel sender gauge.
9. REMOVE EXHAUST PIPE ASSEMBLY FRONT
  • HINT:
  • .
10. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
  • HINT:
  • .
11. REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Remove the 2 nuts and No. 2 differential support protector from the suspension member brace.

12. REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
  • HINT:
  • Removal procedure of the No. 1differential support protector is the same as that of the No. 2 differential support protector.
13. REMOVE NO. 1 FLOOR UNDER COVER
14. REMOVE NO. 2 FLOOR UNDER COVER
15. REMOVE REAR SUSPENSION MEMBER BRACE LH
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Remove the 2 bolts and rear suspension member brace LH.

16. REMOVE REAR SUSPENSION MEMBER BRACE RH
  • HINT:
  • Removal procedure of the RH side is the same as that of the LH side.
17. DISCONNECT PARKING BRAKE CABLE ASSEMBLY
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Remove the 2 parking brake cables from the 4 clamps.

Remove the 4 bolts and disconnect the 2 parking brake cables.

18. DISCONNECT FUEL TUBE SUB-ASSEMBLY
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Disconnect the fuel tank return vent tube.

  • NOTICE:
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.
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Disconnect the fuel tank main tube.

  • NOTICE:
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
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.

20. DISCONNECT FUEL TANK VENT HOSE
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Remove the clamp and disconnect the fuel tank vent hose.

21. REMOVE FUEL TANK ASSEMBLY
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Place a engine lifter under the fuel tank assembly.

Remove the 4 bolts, fuel tank bands and fuel tank assembly.

Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Slightly lower the transmission jack.

Disconnect the fuel tank breather hose and remove the fuel tank assembly.

22. REMOVE NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Remove the 4 bolts, No. 1 fuel tank breather tube sub-assembly and gasket.

23. REMOVE FUEL TUBE SUB-ASSEMBLY
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Disconnect the clamp and remove the fuel tank main tube and fuel tank return vent tube.

Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Disconnect the 2 clamps and remove the edge protector.

24. REMOVE FUEL TANK TO FILLER PIPE HOSE
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Loosen the hose clamp bolt and remove the fuel tank to filler pipe hose from the fuel tank.

25. REMOVE FUEL TANK VENT HOSE
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Remove the clip and fuel tank vent hose.

26. REMOVE FUEL TANK CUSHION
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Remove the 11 fuel tank cushions shown in the illustration.

27. REMOVE NO. 2 FUEL TANK PROTECTOR
Fuel Tank - Removal. 4GR-FSE FUEL. Lexus IS250 IS220d GSE20 ALE20

Remove the No. 2 fuel tank protector from fuel tank assembly.

LEXUS IS250, IS220d / GSE20 ALE20