Lexus ES manuals

Lexus ES: Disassembly

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / 2gr-fks (fuel) / Fuel Pump / Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

NOTICE:

Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube with pump and gauge assembly. Doing so will cause reassembly of the fuel suction tube with pump and gauge assembly to be impossible as the tube is pressed into the fuel suction plate sub-assembly.

*a

Tube

PROCEDURE

1. REMOVE FUEL SENDER GAUGE ASSEMBLY

Click here

2. REMOVE FUEL PUMP WITH FILTER ASSEMBLY

(a) Remove the harness protector from the fuel pump harness.

Harness Protector

Fuel Pump Harness Connector

(b) Disconnect the 2 fuel pump harness connectors.

(c) Disengage the clamp to disconnect the fuel pump harness from the fuel suction plate sub-assembly.

NOTICE:

Do not damage the wire harness.

(d) Using a screwdriver with its tip wrapped with protective tape, disengage the claw.

NOTICE:

Do not damage the fuel sub-tank.

*a

Protective Tape

*b

Fuel Pump Filter Hose

(e) Disengage the clamp and disconnect the fuel pump filter hose from the fuel sub-tank.

NOTICE:

Do not damage the fuel sub-tank.

(f) Disengage the 2 claws and remove the fuel filter from the fuel sub-tank.

NOTICE:

Do not do anything which may separate the tube from either the fuel suction plate sub-assembly or fuel filter, such as applying excessive force to the tube.

Click here

*a

Tube

(g) Using a screwdriver with its tip wrapped with protective tape, disengage the 3 claws, and remove the suction filter from the fuel filter.

NOTICE:

Do not damage the fuel filter or suction filter.

*a

Fuel Filter

*b

Suction Filter

*c

Protective Tape

(h) Disengage the claw to disconnect the fuel pump harness from the suction filter.

(i) Remove the fuel pump from the fuel filter.

(j) Disconnect the fuel pump harness connector to remove the fuel pump harness from the fuel pump.

(k) Remove the O-ring and fuel pump spacer from the fuel pump.

NOTICE:

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.

*1

O-ring

*2

Fuel Pump Spacer

*a

5.0 mm (0.197 in.)

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