TECHNICAL INSTRUCTIONS
FOR
SAFETY RECALL 20LA01
VEHICLE MAY STALL DURING DRIVING AT HIGHER SPEED
| 2018 ES 350 | 2017 IS 200t | 2017 RC 200t |
| 2018 – 2019 GS 300 | 2018 – 2019 IS 300 | 2018 – 2019 RC 300 |
| 2018 – 2019 GS 350 | 2018 – 2019 IS 350 | 2018 – 2019 RC 350 |
| 2019 ES 350 (Japan Built) |
The remedy for this campaign is being launched in phases. Confirm remedy eligibility on each VIN in TIS before starting any repairs.
Update 5/6/2020: Technical Instructions have been updated to include details on new campaign tool
The repair quality of covered vehicles is extremely important to Lexus. All dealership technicians performing this recall 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 recall repair are required to currently hold at least one of the following certification levels:
- Certified
- Senior
- Master
It is the dealership’s responsibility to select technicians with the above certification level or greater to perform this recall 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.
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:
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.
TOOLS & EQUIPMENT
- Standard Hand Tools
- Torque Wrench
- Air Blow gun
MATERIALS
- Brake Cleaner
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 tools are scheduled to arrive between 5/8/20 and 5/11/20. These jaws will be used with the dealerships existing Handle set from the Fuel Sender Lock Nut Wrench Set (0980814031). 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 (not the Campaign Tools) can be purchased through the Lexus Special Service Tools (SST) website.
Special Service Tools
In the affected models, there are two different types of Fuel Pump Retainer Rings.
Reference the following chart to determine the proper SST for each model and retainer type.
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.
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.
TECHNICAL INSTRUCTIONS
FOR
SAFETY RECALL 20LA01
VEHICLE MAY STALL DURING DRIVING AT HIGHER SPEED
2018 ES 350
2017 IS 200t
2017 RC 200t
2018 – 2019 GS 300
2018 – 2019 IS 300
2018 – 2019 RC 300
2018 – 2019 GS 350
2018 – 2019 IS 350
2018 – 2019 RC 350
2019 ES 350 (Japan Built)
The remedy for this campaign is being launched in phases. Confirm remedy eligibility on each VIN in TIS before starting any repairs.
Update 5/6/2020: Technical Instructions have been updated to include details on new campaign tool
The repair quality of covered vehicles is extremely important to Lexus. All dealership technicians performing this recall 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 recall repair are required to currently hold at least one of the following certification levels:
• Certified
• Senior
• Master
It is the dealership’s responsibility to select technicians with the above certification level or greater to perform this recall 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.
2
I. OPERATION FLOW CHART
Verify Vehicle Eligibility1. Confirm vehicle VIN matches the RO.2. Check for Campaign eligibility using TIS.No further action required.Not CoveredCoveredCampaign complete.Return the vehicle to the customer.Remove Fuel Suction Tube Assembly from vehicleDisassemble Fuel Suction Tube AssemblyInstall NEW fuel pumpReassemble Fuel Suction Tube AssemblyReinstall Fuel Suction Tube Assembly into vehicleCheck the Campaign Status of the VIN to determine if Remedy is availableRemedy AvailableThe 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..Remedy Not..Available
3
II. IDENTIFICATION OF AFFECTED VEHICLES
1. CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY
a. Compare the vehicle’s VIN to the VIN listed on the Repair Order to ensure they match.
b. Check the TIS Vehicle Inquiry System or Service Lane to verify this vehicle is eligible for Safety Recall 20LA01.
c. Determine the Campaign Status for Safety Recall 20LA01.
What is the Campaign Status of Safety Recall 20LA01 for this vehicle?DO NOT PROCEED!! Check the VIN again at a later date for Remedy availability.Continue to Section III. PREPARATION on p.4..Remedy NOT Available….Remedy Available..
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.
4
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
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 tools are scheduled to arrive between 5/8/20 and 5/11/20. 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 (not the Campaign Tools) can be purchased through the Lexus Special Service Tools (SST) website.
Campaign Tools
Special Service Tools
Cam Lock Retainer Jaws
Handle
09808-01010
Or suitable 1/2” ratchet
Crossbar
Used With
09808-01030
5
E. Special Service Tools
In the affected models, there are two different types of Fuel Pump Retainer Rings.
Reference the following chart to determine the proper SST for each model and
retainer type.
RETAINER TYPE
Type:
Bolt In
Cam Lock
SST:
No SST
Required
Fuel Sender Lock Nut Wrench Kit (09808-14031)
Claw: 105mm Jaw Set
(09808-01070)
Special Notes:
Campaign Tool:
Cam Lock Retainer Jaws
The tool will require the use of the Handle from the Fuel Sender Lock Nut Wrench Kit, or a 1/2” breaker bar.
Models:
ES 350 (2018)
ES 350 (2019)
GS 300/350
IS 200t/300/350
RC 200t/300/350
Additional SST’s can be purchased from the Toyota Special Service Tools (SST) website.
6
F. 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.
G. SAFETY PRECAUTIONS
CAUTION:
When installing/uninstalling the fuel system components, keep safety first in mind and carefully observe the following instructions to avoid accidents:
a. When working on the fuel system, display a Flammable – Keep Fire Away sign.
b. Smoking is prohibited nearby.
c. Perform this work in an area where there are no sparks nearby from the operation of welders, grinders, drills, electric motors, stoves, etc.
d. DO NOT use electrical devices nearby because they can become hot and the operation of power switches can generate sparks.
e. DO NOT use iron or steel hammers while working, because they may generate sparks.
f. DO NOT start engines even in adjacent stalls.
g. Prepare fire extinguishers before starting any work.
h. Perform this work in a well-ventilated area (natural ventilation). DO NOT use exhaust fans or electric fans, because their motors might generate sparks.
i. Since it is possible for fuel vapor to build up, DO NOT work in or near a pit.
j. 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.
k. 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.
7
H. COMPONENTS
ES 350 2019 (VINs starting JTH)
Replacement Items in red
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.
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
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.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
8
ES 350 2018
Replacement items in red
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
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.
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
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.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
9
GS 300 / GS 350
Replacement items in red
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
16.4mm
7
FUEL TANK PIPE SETTING HOLDER
1
WHITE
*only 1 O-Ring will be used. Discard the 2nd O-Ring.
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
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.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
10
IS 200t / IS 300 / IS 350
Replacement items in red
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
16.4mm
7
FUEL TANK PIPE SETTING HOLDER
1
WHITE
*only 1 O-Ring will be used. Discard the 2nd O-Ring.
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
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.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
11
RC 200t / RC 300 / RC 350
Replacement items in red
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
16.4mm
7
FUEL TANK PIPE SETTING HOLDER
1
WHITE
*only 1 O-Ring will be used. Discard the 2nd O-Ring.
DO NOT order the individual parts listed here. It is provided as a reference to assist in the correct installation. Order the parts kit’s specific to each VIN, as detailed in the parts lookup website (p. 4).
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.
Note: Some items in the Fuel Pump Replacement Kit will not be used.
12
I. REMOVE FUEL TUBE ASSEMBLY
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.
DISASSEMBLY 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.
FUEL LEVEL RECOMMENDATIONS
Model
Less than full
1/3 or less
ES 350
GS 300/350
IS 200t/300/350
RC 200t/300/350
Note: If fuel is removed from the tank, be sure to recover it into a clean storage container as it will be necessary to reinstall this fuel into the vehicle.
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 300
2018
2019
ES 350
2018
2019
GS 350
2018
2019
RC 200t
2017
IS 200t
2017
RC 300
2018
2019
IS 300
2018
2019
RC 350
2018
2019
IS 350
2018
2019
13
J. REMOVE FUEL PUMP FROM TUBE ASSEMBLY
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. The O-Rings are NOT included in the parts kit.
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.
14
DISASSEMBLY 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:
15
DISASSEMBLY TIP: CAM LOCK RETAINER (cont.)
Lightly tighten the adjuster
Fully tighten the 4 bolts
16
1. DISASSEMBLE FUEL SUCTION TUBE ASSEMBLY
a. Follow the Repair Manual instructions to disassemble the Fuel Suction Tube Assembly.
DISASSEMBLE
GS 300
2018
2019
ES 350
2018
2019
GS 350
2018
2019
RC 200t
2017
IS 200t
2017
RC 300
2018
2019
IS 300
2018
2019
RC 350
2018
2019
IS 350
2018
2019
2. CLEAN SUB TANK ASSEMBLY
a. Using brake cleaner, clean the sub-tank assembly.
K. 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, as identified by the tape color.
17
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.
Refer to the Component diagrams at the beginning of these Technical Instructions to confirm the location of each replacement part.
Example Procedure:
HINT:
The reused filter may be discolored.
• 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 to 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.
• Apply engine oil to the NEW O-ring before assembly to assure correct installation into the Fuel Suction Tube.
REASSEMBLE
GS 300
2018
2019
ES 350
2018
2019
GS 350
2018
2019
RC 200t
2017
IS 200t
2017
RC 300
2018
2019
IS 300
2018
2019
RC 350
2018
2019
IS 350
2018
2019
18
L. REINSTALL FUEL TUBE ASSEMBLY
1. INSTALL THE FUEL SUCTION TUBE ASSEMBLY INTO VEHICLE
a. Follow the Repair Manual instructions to reinstall the Fuel Suction Tube into the vehicle.
Refer to the Component diagrams at the beginning of these Technical Instructions to confirm the location of each replacement part.
INSTALLATION
GS 300
2018
2019
ES 350
2018
2019
GS 350
2018
2019
RC 200t
2017
IS 200t
2017
RC 300
2018
2019
IS 300
2018
2019
RC 350
2018
2019
IS 350
2018
2019
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.
19
1919 = 201920 = 202021 = 202122 = 202223 = 2023Etc…Year Campaignis Launched19TA01TT = ToyotaL = LexusVehicle MakeAA = Safety Recall RemedyB = Safety Recall InterimC = Special Service CampaignD = Limited Service CampaignE = Customer Support ProgramF = Emissions Recall(May use other characters in unique cases)Field Action Category and Phase0101 = 1st Field Action of the year02 = 2nd Field Action of the year03 = 3rd Field Action of the year(The sequence is unique for each Field Action category)(May use other characters in unique cases)Field Action Sequence
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
M. 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
Remedy Instructions and TSB
RCRIT-20V012-3935.pdf 1110.29KB
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- WHEN DO I WEAR THIS - This women's t-shirt is great for making a statement. You can say things without even saying them out loud. Walk proudly and people will most likely stop and compliment your witty sense and your great women's t-shirt!
- FEELS GREAT - Our men's hoodie is constructed from 90% cotton and 10% polyester making this one of the most comfortable and soft hoodies on the market. With its heavy 9.7oz weight it keeps you feeling comfortable and warm in those cold conditions.
- FIT AND FUNCTION - Our men's hoodie features a normal to large men's fit. With its high-stitch density, jersey-lined two-ply hood, double-needle coverseamed armholes and waistband, and its extra roomy front pouch pocket it is built to last and be highly functional.
- A GREAT GIFT - This hoodie makes a wonderful gift for a Birthday, Mother's Day, Father's Day, Christmas, or any gift giving holiday. It also makes an amazing wedding party gift for those bachelor or bachelorette parties, an office gift, a gift for your boss, or any other special occasion when you might just need something for a laugh.
- WHEN TO WEAR - Great for any present or occasion such as yard work, camping, or even a fun night on the town, a trip to your local dive bar, or anything where you need something casual yet classy.
Last update on 2021-01-22 / Affiliate links / Images from Amazon Product Advertising API
Last update on 2021-01-22 / Affiliate links / Images from Amazon Product Advertising API
