IMPORTANT UPDATE
TECHNICAL INSTRUCTIONS
FOR
SAFETY RECALL 20LA01
VEHICLE MAY STALL DURING DRIVING AT HIGHER SPEED
Affected Models:
- 2018-2019 GS 300
- 2013-2015 GS 350
- 2017-2019 GS 350
- 2018-2020 LC 500
- 2018-2020 LC 500h
- 2017-2020 RX 350
- 2018-2020 RX 350L
- 2014-2015 LX 570
- 2018-2019 LX 570
- 2017 IS 200t
- 2018-2019 IS 300
- 2014-2015 IS 350
- 2018-2019 IS 350
- 2018-2020 ES 350
- 2013-2015 LS 460
- 2017 GS 200t
- 2019 UX 200
- 2014-2015 GX 460
- 2018-2019 GX 460
- 2017 RC 200t
- 2018-2019 RC 300
- 2015 RC 350
- 2018-2019 RC 350
- 2018-2020 LS 500
- 2018-2019 LS 500h
- 2018-2019 NX 300
- 2015 NX 200t
- 2014 IS-F
The remedy for this campaign is being launched in phases. Confirm remedy eligibility on each VIN in TIS before starting any repairs.
Updates to Recall 20LA01:
- Update 7/1/2021: Technician qualifications to perform this recall have been updated.
- Update 3/31/2021: 2018 – 2019 GX 460 models added.
- Update 3/25/2021: 2019 NX 300 model added.
- Update 3/18/2021: 2018 – 2019 LX 570 models added.
- Update 2/25/2021: 2018 NX 300; 2020 RX 350 / RX 450L added.
- Update 2/18/2021: 2019 UX 200 model added.
- Update 2/10/2021: Instructions added for use of Retainer Ring Pilers.
- Update 2/10/2021: Tips added for Removal, Disassembly and Reassembly.
- Update 1/13/2021: 2017 GS 200t, GS350; 2020 ES 350, LS 500, LC 500 and LC 500h models added.
- Update 10/22/2020: LX 570 has been added.
- Update 6/26/2020: NX 200t, 2013-2015 GS 350, 2014-2015 IS 350, 2015 RC 350, 2013-2015 LS 460 models have been added.
- Update 6/16/2020: GX, ES (US built), RX models have been added.
- Update 5/22/2020: LS, LC & IS-F models have been added.
- Update 5/6/2020: Details of the NEW Cam Lock style campaign tool have been added.
Technician Requirements:
The repair quality of covered vehicles is extremely important to Lexus. All dealership technicians performing this repair are required to successfully complete the most current version of the E-Learning course "Safety Recall and Service Campaign Essentials". To ensure that all vehicles have the repair performed correctly, technicians performing this repair are required to currently have completed all of the following courses:
- L623 Electrical Circuit Diagnosis
It is the dealership's responsibility to select technicians that have completed the above courses to perform this repair. Carefully review your resources, the technician skill level, and ability before assigning technicians to this repair. It is important to consider technician days off and vacation schedules to ensure there are properly trained technicians available to perform this repair at all times.
I. OPERATION FLOW CHART
Verify Vehicle Eligibility:
- Confirm vehicle VIN matches the RO.
- Check for Campaign eligibility using TIS.
If vehicle is Not Covered, no further action is required.
If vehicle is Covered:
- Check the Campaign Status of the VIN to determine if Remedy is available.
If Remedy is Available:
- Remove Fuel Suction Tube Assembly from vehicle.
- Disassemble Fuel Suction Tube Assembly.
- Install NEW fuel pump.
- Reassemble Fuel Suction Tube Assembly.
- Reinstall Fuel Suction Tube Assembly into vehicle.
Campaign complete. Return the vehicle to the customer.
If Remedy is Not Available: The Remedy for this vehicle is not available at this time. Refer to the Lexus Dealer Letter for Remedy Launch timing for this model (20LA01 Dealer Letter).
II. IDENTIFICATION OF AFFECTED VEHICLES
1. CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY
- Compare the vehicle's VIN to the VIN listed on the Repair Order to ensure they match.
- Check the TIS Vehicle Inquiry System or Service Lane to verify this vehicle is eligible for Safety Recall 20LA01.
- Determine the Campaign Status for Safety Recall 20LA01.
What is the Campaign Status of Safety Recall 20LA01 for this vehicle?
- If Remedy Available: Continue to Section III. PREPARATION on p.4.
- If Remedy NOT Available: DO NOT PROCEED!! Check the VIN again at a later date for Remedy availability.
DO NOT PROCEED with these instructions if the Campaign Status shows Remedy Not Available!
The remedy for this campaign is being launched in phases. Confirm remedy eligibility on each VIN in TIS before starting any repairs. Launch timing specific to each model is available in the 20LA01 Dealer Letter.
Note: Warranty will not reimburse dealers for repairs completed on vehicles that are not affected or were previously completed, even by another dealer. In addition, warranty claims will not be processed for vehicles that are not yet eligible for the remedy.
III. PREPARATION
A. PARTS
Because of the extensive list of parts for the numerous models affected by this Safety Recall, a website has been created to detail the required parts for each vehicle. Reference the following website for a detailed parts list for each specific VIN: https://20la01.imagespm.info
Note: Warranty will only reimburse dealers for the part numbers listed on the website. Any other part numbers will not be accepted on the campaign claim.
B. TOOLS & EQUIPMENT
- Standard Hand Tools
- Torque Wrench
- Air Blow gun
- Gas Caddy (minimum 25-gallon capacity)
C. MATERIALS
- Brake Cleaner
D. CAMPAIGN TOOLS
Each dealership will be provided a Crossbar and a set of Cam Lock Retainer Jaws for removing the Cam Lock type retainer rings. These jaws will be used with the dealerships existing Handle set from the Fuel Sender Lock Nut Wrench Set (09808-14031). A 1/2" breaker bar can also be used. This set of tools will supplement the SST kit that each dealership currently has. Additional SST's can be purchased through the Lexus Special Service Tools (SST) website.
Campaign Tools:
- Cam Lock Retainer Jaws
- Crossbar
- Retainer Ring Pliers (Shipped to dealerships in early February 2021)
Special Service Tools:
- Handle (Used with Cam Lock Retainer Jaws)
- 09808-01010 (Or suitable 1/2" breaker bar)
E. Special Service Tools
In the affected models, there are four different types of Fuel Pump Retainer Rings. Reference the following chart to determine the proper tool for removal.
Type: | Bolt In | Cam Lock | Plastic Ring | Plastic Ring w/ Holding Tool |
---|---|---|---|---|
SST: | No SST Required | Fuel Sender Lock Nut Wrench Kit (09808-14031) Claw: 105mm Jaw Set (09808-01070) Crossbar (09808-01030) |
Fuel Sender Lock Nut Wrench Kit (09808-14031) Option 1: Claw: 50mm Jaw Set (09808-01040) Option 2: Claw: Sliding jaw (09808-01080) Crossbar (09808-01030) |
Fuel Pump Retainer Tool (*e) (09808-14040) Fuel Pump Holding Tool (*d) (09808-14050) |
Campaign Tool: | Cam Lock Retainer Jaws | |||
Aftermarket alternative: | CTA Tools 1044 Fuel Tank Lid Wrench | |||
Special Notes: | Requires use of the Handle from the Fuel Sender Lock Nut Wrench Kit, or a 1/2" breaker bar. | This tool is available from Autopart.com Or contact CTA Tools at info@ctatools.com for purchasing inquiries |
Additional SST's can be purchased from the Lexus Special Service Tools (SST) website | |
Models: | ES 350 (2018) LC 500/500h LS 500/500h LS 460 IS-F NX 200t / 300 |
ES 350 (2019 & 2020) GS 300/350 IS 200t/300/350 RC 200t/300/350 UX 200 |
GX 460 LX 570 |
RX 350/350L |
IV. BACKGROUND
The subject vehicles are equipped with a low-pressure fuel pump which may stop operating. If this were to occur, warning lights and messages may be displayed on the instrument panel, and the engine may run rough. This may result in a vehicle stall, and the vehicle may be unable to be restarted. If a vehicle stall occurs while driving at higher speeds, this could increase the risk of a crash.
Diagram Description (Fuel Pump Assembly): The diagram shows the fuel pump assembly, including the fuel tank vent tube set plate (retainer), fuel suction tube assembly, and fuel tank. A separate callout shows the part to be replaced: the Fuel Pump, with a note to "BE CAREFUL! Reuse the filter."
V. SAFETY PRECAUTIONS
CAUTION: When installing/uninstalling the fuel system components, keep safety first in mind and carefully observe the following instructions to avoid accidents:
- When working on the fuel system, display a Flammable - Keep Fire Away sign.
- Smoking is prohibited nearby.
- Perform this work in an area where there are no sparks nearby from the operation of welders, grinders, drills, electric motors, stoves, etc.
- DO NOT use electrical devices nearby because they can become hot and the operation of power switches can generate sparks.
- DO NOT use iron or steel hammers while working, because they may generate sparks.
- DO NOT start engines even in adjacent stalls.
- Prepare fire extinguishers before starting any work.
- Perform this work in a well-ventilated area (natural ventilation). DO NOT use exhaust fans or electric fans, because their motors might generate sparks.
- Since it is possible for fuel vapor to build up, DO NOT work in or near a pit.
- If fuel is spilled, use shop towels or similar material to quickly wipe it up and then use compressed air to diffuse the fuel vapor.
- Shop towels and other materials that have come into contact with fuel should be dried in a well-ventilated area and then disposed of as appropriate.
VI. COMPONENTS
ES 350 2019 & 2020 (VINs starting JTH)
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), Rear Seat Cushion Lock Hook (4), O-Rings (5, 6), Fuel Tank Pipe Setting Holder (7).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 2* | GOLD | 15.2mm |
4 | REAR SEAT CUSHION LOCK HOOK | 2 | ||
5 | O-RING | 1 | RED | Not used |
6 | O-RING | 1 | GREEN | Not used |
7 | FUEL TANK PIPE SETTING HOLDER | 1 | WHITE | Not used |
*Only 1 O-Ring will be used. Discard the 2nd O-Ring.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
ES 350 2019 & 2020 (VINs starting 58A)
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), Rear Seat Cushion Lock Hook (4), O-Rings (5, 6), Fuel Tank Pipe Setting Holder (7), Rear Seat Cushion Lock Hook (8).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 2* | Gold | 15.2mm |
4 | REAR SEAT CUSHION LOCK HOOK | 2 | Not used | |
5 | O-RING | 1 | Red | Not used |
6 | O-RING | 1 | Green | Not used |
7 | FUEL TANK PIPE SETTING HOLDER | 1 | White | Not used |
8 | REAR SEAT CUSHION LOCK HOOK | 2 | Not used |
*Only 1 O-Ring will be used. Discard the 2nd O-Ring.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
ES 350 2018
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), Rear Seat Cushion Lock Hook (4), O-Rings (5, 6), Fuel Tank Pipe Setting Holder (7).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 2* | YELLOW | 15.2mm |
4 | REAR SEAT CUSHION LOCK HOOK | 2 | Not used | |
5 | O-RING | 1 | RED | Not used |
6 | O-RING | 1 | GREEN | Not used |
7 | FUEL TANK PIPE SETTING HOLDER | 1 | WHITE | Not used |
*Only 1 O-Ring will be used. Discard the 2nd O-Ring.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
GS 200t / GS 300 / GS 350
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), Rear Seat Cushion Lock Hook (4), O-Rings (5, 6), Fuel Tank Pipe Setting Holder (7).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 2* | GOLD | 15.2mm |
4 | REAR SEAT CUSHION LOCK HOOK | 2 | Not used | |
5 | O-RING | 1 | RED | Not used |
6 | O-RING | 1 | GREEN | 16.4mm |
7 | FUEL TANK PIPE SETTING HOLDER | 1 | WHITE |
*Only 1 O-Ring will be used. Discard the 2nd O-Ring.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
GX 460
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), Fuel Pump Gauge Retainer (4).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 1 | Yellow | 15.2mm |
4 | FUEL PUMP GAUGE RETAINER | 1 |
IS 200t / IS 300 / IS 350
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), Rear Seat Cushion Lock Hook (4), O-Rings (5, 6), Fuel Tank Pipe Setting Holder (7).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 2* | GOLD | 15.2mm |
4 | REAR SEAT CUSHION LOCK HOOK | 2 | Not used | |
5 | O-RING | 1 | RED | Not used |
6 | O-RING | 1 | GREEN | 16.4mm |
7 | FUEL TANK PIPE SETTING HOLDER | 1 | WHITE |
*Only 1 O-Ring will be used. Discard the 2nd O-Ring.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
IS-F
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), Rear Seat Cushion Lock Hook (4), O-Ring (5), O-Ring (6), Fuel Tank Pipe Setting Holder (7).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 2* | Gold | 15.2mm |
4 | REAR SEAT CUSHION LOCK HOOK | 4** | 2 needed | |
5 | O-RING | 1 | Red | Not used |
6 | O-RING | 1 | Green | 16.4mm |
7 | FUEL TANK PIPE SETTING HOLDER | 1 | White |
*Only 1 O-Ring will be used. Discard the 2nd O-Ring.
**Only 2 rear seat lock hooks are needed. Discard the other 2.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
LS 460 / LS 460L
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), Rear Seat Cushion Lock Hook (4), O-Ring (5), O-Ring (6), Fuel Tank Pipe Setting Holder (7).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 2* | Gold | 15.2mm |
4 | REAR SEAT CUSHION LOCK HOOK | 4** | varies | |
5 | O-RING | 1 | Red | Not used |
6 | O-RING | 1 | Green | 16.4mm |
7 | FUEL TANK PIPE SETTING HOLDER | 1 | White |
*Only 1 O-Ring will be used. Discard the 2nd O-Ring.
**Fixed rear seat will use 3 pieces. Power rear seat will use 4 pieces.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
LC 500 / LC 500h LS 500 / LS 500h
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), Rear Seat Cushion Lock Hook (4), O-Ring (5), O-Ring (6), Fuel Tank Pipe Setting Holder (7).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 2* | Gold | 15.2mm |
4 | REAR SEAT CUSHION LOCK HOOK | 4** | varies | |
5 | O-RING | 1 | Red | Not used |
6 | O-RING | 1 | Green | 16.4mm |
7 | FUEL TANK PIPE SETTING HOLDER | 1 | White |
*Only 1 O-Ring will be used. Discard the 2nd O-Ring.
** LS 500/500h: Fixed rear seat will use 3 pieces. Power rear seat will use 2 pieces.
** LC 500/500h: Only 2 rear seat lock hooks are needed. Discard the other 2.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
LX 570
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), Fuel Pump Gauge Retainer (4), Tube Joint Clip (5).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 1 | Yellow | 15.2mm |
4 | FUEL PUMP GAUGE RETAINER | 1 | ||
5 | TUBE JOINT CLIP | 16 |
NX 200t 2015 NX 300 2018
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), O-Ring (4), O-Ring (5), O-Ring (6), Fuel Tank Pipe Setting Holder (7).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 1 | Yellow | 15.2mm |
4 | O-RING | 1 | Red | Not used |
5 | O-RING | 1 | Sky Blue | Not used |
6 | O-RING | 1 | Green | 16.4mm |
7 | FUEL TANK PIPE SETTING HOLDER | 1 | White |
Note: Some items in the Fuel Pump Replacement Kit will not be used.
NX 300 2019
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), O-Ring (4), Fuel Tank Pipe Setting Holder (5).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 1 | Yellow | Approx. OD 15.2 mm |
4 | O-RING | 1 | Green | Approx. OD 16.4 mm |
5 | FUEL TANK PIPE SETTING HOLDER | 1 | White |
RC 200t / RC 300 / RC 350
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), Rear Seat Cushion Lock Hook (4), O-Ring (5), O-Ring (6), Fuel Tank Pipe Setting Holder (7).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 2* | GOLD | 15.2mm |
4 | REAR SEAT CUSHION LOCK HOOK | 2 | Not used | |
5 | O-RING | 1 | RED | Not used |
6 | O-RING | 1 | GREEN | 16.4mm |
7 | FUEL TANK PIPE SETTING HOLDER | 1 | WHITE |
*Only 1 O-Ring will be used. Discard the 2nd O-Ring.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
RX 350 / RX 350L
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), Fuel Pump Gauge Retainer (4), Fuel Tank Pipe Setting Holder (5).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 1 | Yellow | 15.2mm |
4 | FUEL PUMP GAUGE RETAINER | 1 | ||
5 | FUEL TANK PIPE SETTING HOLDER | 1 | White |
UX 200
Diagram Description: Exploded view of the fuel pump assembly. Replacement items are indicated in red. Components shown are: Fuel Pump (1), Fuel Suction Tube Set Gasket (2), O-Ring (3), Rear Seat Cushion Lock Hook (4), O-Ring (5), O-Ring (6), Fuel Tank Pipe Setting Holder (7).
No. | Contents of Part Kit's | Quantity | Tape Color | Remarks |
---|---|---|---|---|
1 | FUEL PUMP | 1 | ||
2 | FUEL SUCTION TUBE SET GASKET | 1 | ||
3 | O-RING | 2* | GOLD | 15.2mm |
4 | REAR SEAT CUSHION LOCK HOOK | 2 | Not Used | |
5 | O-RING | 1 | RED | Not Used |
6 | O-RING | 1 | GREEN | Not Used |
7 | FUEL TANK PIPE SETTING HOLDER | 1 | WHITE | Not Used |
*Only 1 O-Ring will be used. Discard the 2nd O-Ring.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
VII. REMOVE FUEL TUBE ASSEMBLY
STOP Use TIS to confirm that this vehicle is eligible for the campaign before proceeding (p. 3). Warranty will not pay claims on ineligible vehicles.
1. CHECK FOR DTC'S
a. Using a Techstream, perform a Health Check to check for Diagnostic Trouble Codes.
Note: This Safety Recall covers only the replacement of the fuel pump and associated parts. It does not cover the diagnosis or replacement of any other parts on the vehicle.
REMOVAL TIP: FUEL LEVEL
If the fuel level inside the fuel tank is above the specified level, fuel may overflow from the fuel tank during the removal of the fuel suction tube assembly. Confirm the fuel level in the vehicle is below the specified level before proceeding. If necessary, drain fuel from the tank.
Model | Less than full | 1/3 or less |
---|---|---|
ES 350 GX 460 RX 350/350L LX 570 UX 200 |
✔️ | |
GS 200t/300/350 IS 200t/300/350 IS-F LC 500/500h LS 500/500h LS 460 NX 200t / NX 300 RC200t/300/350 |
✔️ |
Note: If fuel needs to be removed from the tank, be sure to recover it into an approved fuel recovery system. Suitable systems are available from the Lexus Approved Dealer Equipment website.
REMOVAL TIP: CAM LOCK RETAINER
An updated set of Cam Lock Claws and Support Columns are being supplied to each dealership for this campaign. The configuration of the retainer engagement sections of the claws have been modified from the SST that is referenced in the repair manual. The NEW claws have an improved design that enables a firm attachment to the retainer. In addition, 2 support columns are provided which will support the retainer more securely during installation and removal. Be sure to assemble and use the tools using the following procedures:
Campaign Tool Cam Lock Set:
Diagram Description: Illustrates the assembly of the Cam Lock Set, showing the Adjuster, Claw, Adjuster Plate, and Bolt. It also shows side views and top views of the assembly process, including checks for proper fitment (OK/NG) and tightening procedures.
REMOVAL TIP: CAM LOCK RETAINER (cont.)
Diagram Description: Shows the process of pushing the claw inward firmly and checking for engagement with the retainer. It also illustrates correct (OK) and incorrect (NG) alignment of the claw with the retainer. Finally, it depicts the steps for lightly tightening the adjuster and fully tightening the 4 bolts.
REMOVAL TIP: RETAINER RING REMOVAL
In early February 2021, each dealership was sent one (1) pair of Retainer Ring Plier's. These tools can be used for separating the bond between the Retainer Ring and Fuel Tube Assembly if necessary.
REMOVAL PROCEDURE
- Using the pliers provided, release the adhesion between the Retaining Ring and the Fuel Tube Assembly around the entire circumference.
- Using the SST, loosen the Retainer Ring.
Diagram Description: Shows a retainer ring with adhesion points and a cross-sectional view demonstrating the use of pliers to release adhesion and loosen the retainer.
REMOVAL TIP: TUBE ASSY ALIGNMENT
For vehicles with the plastic retainer rings, place matchmarks on both the Fuel Tube Assembly and the fuel tank. During disassembly, confirm that the Fuel Tube Assembly does not rotate. Damage to the fuel level float arm could occur if the Fuel Tube Assembly is allowed to rotate during disassembly or reassembly. During reassembly, this will aid in aligning the locating tabs for proper installation.
Diagram Description: Shows placing matchmarks on the fuel tube assembly and fuel tank, and aligning them.
REMOVAL TIP: TUBE ASSY REMOVAL
- Slightly raise the fuel suction tube assembly during this operation to make sure that the sender gauge does not interfere with the inside of tank.
- Pull up the fuel suction tube assembly to the position indicated in the illustration. Pull portion (A) by hand to swing the lower part of fuel suction tube assembly downward, and then remove the fuel suction tube assembly from the tank.
- DO NOT bend the arm of fuel sender gauge assembly.
- DO NOT damage the wire harness at edges of service hole when removing the fuel suction tube assembly.
Diagram Description: Shows the fuel suction tube assembly being raised and pulled out of the tank, illustrating portion (A) and the upper surface of the tank.
2. REMOVE FUEL TUBE ASSEMBLY FROM VEHICLE
a. Follow the Repair Manual instructions to remove the Fuel Tube Assembly from the vehicle.
REMOVE FUEL TUBE ASSY.
GS 350 | 2013 | 2014 | 2015 | 2017 | 2018 | 2019 | IS 300 | 2018 | 2019 |
LX 570 | 2014 | 2015 | 2018 | 2019 | LS 500h | 2018 | 2019 | ||
IS 350 | 2014 | 2015 | 2018 | 2019 | RC 300 | 2018 | 2019 | ||
RX 350 (VIN JTJ) | 2017 | 2018 | 2019 | 2020 | NX 300 | 2018 | 2019 | ||
RX 350 (VIN 2T2) | 2017 | 2018 | 2019 | 2020 | GS 300 | 2018 | 2019 | ||
GX 460 | 2014 | 2015 | 2018 | 2019 | UX 200 | 2019 | |||
RC 350 | 2015 | 2018 | 2019 | GS 200t | 2017 | ||||
LS 460 | 2013 | 2014 | 2015 | IS 200t | 2017 | ||||
ES 350 | 2018 | 2019 | 2020 | IS-F | 2014 | ||||
LC 500 | 2018 | 2019 | 2020 | RC 200t | 2017 | ||||
LS 500 | 2018 | 2019 | 2020 | NX 200t | 2015 | ||||
LC 500h | 2018 | 2019 | 2020 |
VIII. DISASSEMBLE FUEL TUBE ASSEMBLY
DISASSEMBLY TIP: FOLLOW THE REPAIR MANUAL
The Part's Kit contains the necessary O-Rings for reassembly, if the Repair Manual procedure is followed. If the pump components are disassembled in a manor other than as detailed in the Repair Manual, the Parts Kit may not contain the necessary O-Rings for proper reassembly. Please follow the procedures in the Repair Manual to ensure the correct O-Rings are available.
Example of Proper Disassembly:
Diagram Description: Shows the correct method using a screwdriver wrapped in protective tape to remove the jet pump from the fuel sub-tank. The tube is shown still attached, and the jet pump is properly removed. A note indicates where the replacement O-Ring will be installed.
Example of Incorrect Disassembly:
Diagram Description: Shows incorrect disassembly where the tube is removed incorrectly from the jet pump, and the replacement O-ring is the incorrect size. Another image shows the tube not disconnected from the jet pump, with a note that the replacement O-Ring is not provided for that location.
DISASSEMBLY TIP: MAIN VALVE AND REGULATOR
When replacing the fuel pump, it is not necessary to remove the Fuel Main Valve or Fuel Pressure Regulator. These O-Rings are NOT included in the parts kit.
Diagram Description: Shows O-Rings for the Fuel Main Valve and Fuel Pressure Regulator assemblies, with a comparison of correct and incorrect main valve assemblies.
DISASSEMBLY TIPS: FUEL FILTER
Many of the models will require the fuel filter to be reused. Be careful with the tabs when removing the filter from the original fuel pump as to not overextend them. When installing the filter on the NEW Fuel Pump, be sure that the clips have engaged properly.
Diagram Description: Shows a fuel filter with tabs.
DISASSEMBLY TIP: FUEL LEVEL SENDER
When removing and reinstalling the Fuel Level Sender from the fuel tank, take extra care with the arm of the fuel sender. It can be easily bent. Additionally, do not touch the electric circuit of the sender assembly.
Diagram Description: Highlights the fuel sender gauge, showing areas not to touch (electric circuit) and not to deform (arm).
DISASSEMBLY TIPS: O-RING REMOVAL
During disassembly, the O-Ring may remain in the fuel pump housing. Be sure to inspect the housing after removing the fuel pump and remove the O-Ring if necessary.
1. DISASSEMBLE FUEL SUCTION TUBE ASSEMBLY
a. Follow the Repair Manual instructions to disassemble the Fuel Suction Tube Assembly.
DISASSEMBLE
GS 350 | 2013 | 2014 | 2015 | 2017 | 2018 | 2019 | IS 300 | 2018 | 2019 |
LX 570 | 2014 | 2015 | 2018 | 2019 | LS 500h | 2018 | 2019 | ||
IS 350 | 2014 | 2015 | 2018 | 2019 | RC 300 | 2018 | 2019 | ||
RX 350 (VIN JTJ) | 2017 | 2018 | 2019 | 2020 | NX 300 | 2018 | 2019 | ||
RX 350 (VIN 2T2) | 2017 | 2018 | 2019 | 2020 | GS 300 | 2018 | 2019 | ||
GX 460 | 2014 | 2015 | 2018 | 2019 | UX 200 | 2019 | |||
RC 350 | 2015 | 2018 | 2019 | GS 200t | 2017 | ||||
LS 460 | 2013 | 2014 | 2015 | IS 200t | 2017 | ||||
ES 350 | 2018 | 2019 | 2020 | IS-F | 2014 | ||||
LC 500 | 2018 | 2019 | 2020 | RC 200t | 2017 | ||||
LS 500 | 2018 | 2019 | 2020 | NX 200t | 2015 | ||||
LC 500h | 2018 | 2019 | 2020 |
2. CLEAN SUB TANK ASSEMBLY
a. Using brake cleaner, clean the sub-tank assembly.
Diagram Description: Shows cleaning the sub-tank assembly with brake cleaner.
IX. REASSEMBLE FUEL TUBE ASSEMBLY
REASSEMBLY TIPS: O-RINGS
The part kits may come with O-Rings of different sizes. They are very difficult to tell apart visually. To identify the different size O-Rings, they will be wrapped in individual plastic bags with a piece of COLORED TAPE sealing it. The COLOR OF THE TAPE will identify the O-Ring size. REFER TO THE COMPONENT DIAGRAMS TO DETERMINE TO CORRECT O-RING.
Diagram Description: Shows O-rings in plastic bags with colored tape.
REASSEMBLY TIPS: FUEL TUBE
When assembling the upper and lower sections of the fuel pump assembly, be certain to correctly align the upper and lower sections as to not twist the fuel tube.
Diagram Description: Shows incorrect alignment (circled in red) and correct alignment of the fuel pump assembly sections.
REASSEMBLY TIPS: FUEL FILTER INSTALLATION
When assembling the fuel filter retainer to pump housing on some models, there is a possibility that the main valve will unseat itself from the housing. Be sure to inspect the complete assembly for the following issues:
- Crack in the retainer
- Claws are properly engaged
- O-Ring is properly seated
- No gap between the housing and main valve
Diagram Description (Incorrect Assembly): Shows incorrect conditions: a crack in the retainer, retainer claw below attachment point, incorrect position of O-Ring, and a gap visible between housing and valve.
Diagram Description (Correct Assembly): Shows good condition: retainer claw secured above attachment point, and no visible gap or O-Ring between valve and housing.
1. CONFIRM PARTS
a. Using the part lookup website, input the VIN number to confirm that you have the proper parts for this vehicle: https://20la01.imagespm.info
2. REASSEMBLE FUEL SUCTION TUBE ASSEMBLY WITH NEW FUEL PUMP
a. Follow the Repair Manual instructions to reassemble the Fuel Suction Tube Assembly with a NEW Fuel Pump.
STOP Refer to the component diagrams at the beginning of these Technical Instructions to confirm the location of each replacement part.
Example Procedure:
- Remove the original O-Ring, Spacer and Fuel Filter from the original Fuel Pump.
- Discard the original O-Ring and Fuel Pump, saving the Spacer and Fuel Filter.
- Install the original Spacer onto the NEW Fuel Pump.
- Install the NEW O-Ring onto the NEW Fuel Pump. Refer to the Component Diagram to determine the proper O-Ring, as identified by the colored tape on the bag.
- Apply a small amount of engine oil to the NEW O-Ring to assure correct installation into the Tube Assembly.
- Install the original Fuel Filter onto the NEW Fuel Pump.
- Refer to the Components diagrams to review the other NEW parts to install.
HINT: The reused filter may be discolored.
Apply engine oil to the NEW O-ring before assembly to assure correct installation into the Fuel Suction Tube.
Note: Fuel Pump O-Ring installation is critical to this repair. A visual inspection of the final assembly will confirm the correct installation.
Diagram Description: Shows good condition (O-ring and spacer assembly in correct order, O-ring not tilted, correct thin O-ring used) and incorrect conditions (assembly in reverse order, O-ring tilted, wrong thin O-ring used).
3. REASSEMBLE FUEL SUCTION TUBE ASSEMBLY
b. Follow the Repair Manual instructions to reassemble the Fuel Suction Tube Assembly.
REASSEMBLE
GS 350 | 2013 | 2014 | 2015 | 2017 | 2018 | 2019 | IS 300 | 2018 | 2019 |
LX 570 | 2014 | 2015 | 2018 | 2019 | LS 500h | 2018 | 2019 | ||
IS 350 | 2014 | 2015 | 2018 | 2019 | RC 300 | 2018 | 2019 | ||
RX 350 (VIN JTJ) | 2017 | 2018 | 2019 | 2020 | NX 300 | 2018 | 2019 | ||
RX 350 (VIN 2T2) | 2017 | 2018 | 2019 | 2020 | GS 300 | 2018 | 2019 | ||
GX 460 | 2014 | 2015 | 2018 | 2019 | UX 200 | 2019 | |||
RC 350 | 2015 | 2018 | 2019 | GS 200t | 2017 | ||||
LS 460 | 2013 | 2014 | 2015 | IS 200t | 2017 | ||||
ES 350 | 2018 | 2019 | 2020 | IS-F | 2014 | ||||
LC 500 | 2018 | 2019 | 2020 | RC 200t | 2017 | ||||
LS 500 | 2018 | 2019 | 2020 | NX 200t | 2015 | ||||
LC 500h | 2018 | 2019 | 2020 |
X. INSTALL FUEL TUBE ASSEMBLY
INSTALLATION TIP: PLASTIC RETAINER
Set NEW gasket properly. DO NOT apply silicon grease.
Diagram Description: Shows correct (OK) and incorrect (NG) gasket installation on the retainer, indicating the gasket placement relative to the tank.
Put the retainer around the arm so that it is not necessary to change hands to keep pressing down the fuel suction tube. (Plastic Retainer)
Keep pressing down the fuel suction tube while installing the retainer.
Diagram Description: Shows placing the retainer around the arm and pressing down the fuel suction tube while installing the retainer, with an alignment indicator.
1. INSTALL THE FUEL SUCTION TUBE ASSEMBLY INTO VEHICLE
a. Follow the Repair Manual instructions to reinstall the Fuel Suction Tube into the vehicle.
STOP Refer to the Component diagrams at the beginning of these Technical Instructions to confirm the location of each replacement part.
INSTALLATION
GS 350 | 2013 | 2014 | 2015 | 2017 | 2018 | 2019 | IS 300 | 2018 | 2019 |
LX 570 | 2014 | 2015 | 2018 | 2019 | LS 500h | 2018 | 2019 | ||
IS 350 | 2014 | 2015 | 2018 | 2019 | RC 300 | 2018 | 2019 | ||
RX 350 (VIN JTJ) | 2017 | 2018 | 2019 | 2020 | NX 300 | 2018 | 2019 | ||
RX 350 (VIN 2T2) | 2017 | 2018 | 2019 | 2020 | GS 300 | 2018 | 2019 | ||
GX 460 | 2014 | 2015 | 2018 | 2019 | UX 200 | 2019 | |||
RC 350 | 2015 | 2018 | 2019 | GS 200t | 2017 | ||||
LS 460 | 2013 | 2014 | 2015 | IS 200t | 2017 | ||||
ES 350 | 2018 | 2019 | 2020 | IS-F | 2014 | ||||
LC 500 | 2018 | 2019 | 2020 | RC 200t | 2017 | ||||
LS 500 | 2018 | 2019 | 2020 | NX 200t | 2015 | ||||
LC 500h | 2018 | 2019 | 2020 |
2. REMOVED FUEL
a. If fuel was removed from the tank prior to disassembly, reinstall the originally recovered fuel into the tank.
3. CHECK FOR DTC'S
a. Using a Techstream, perform a Health Check to check for Diagnostic Trouble Codes.
Note: This Safety Recall covers only the replacement of the fuel pump and associated parts. It does not cover the diagnosis or replacement of any other parts on the vehicle.
VERIFY REPAIR QUALITY
- Confirm no fuel leaks from vehicle.
- Confirm any fuel drained from the vehicle has been reinstalled.
- Test drive to confirm normal operation while under load.
- Confirm no DTC's are present.
- Confirm that all parts listed in the Components Diagrams have been properly installed on the vehicle.
XI. APPENDIX
A. PARTS DISPOSAL
In accordance with Federal law, please make sure all recalled parts (original parts) removed from the vehicle are disposed of in a manner in which they will not be reused, unless requested for parts recovery return.
B. CAMPAIGN DESIGNATION DECORDER
Diagram Description: The campaign designation format is shown as 19TA01, broken down into components: Year Campaign is Launched (e.g., 19 = 2019), Vehicle Make (T = Toyota, L = Lexus), Field Action Category and Phase (A = Safety Recall Remedy, B = Safety Recall Interim, etc.), and Field Action Sequence (e.g., 01 = 1st Field Action of the year).
Examples:
- 19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019.
- 20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020.
- 21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021.