Vehicle May Stall During Driving At Higher Speed – 2013-2020 Lexus

SEOCONTENT-START

IMPORTANT UPDATE TECHNICAL INSTRUCTIONS FOR SAFETY RECALL 20LA01 VEHICLE MAY STALL DURING DRIVING AT HIGHER SPEED 2018 – 2019 GS 300 2017 IS 200t 2017 RC 200t 2013 – 2015 GS 350 2018 – 2019 IS 300 2018 – 2019 RC 300 2017 – 2019 GS 350 2014 – 2015 IS 350 2015 RC 350 2018 – 2020 LC 500 2018 – 2019 IS 350 2018 – 2019 RC 350 2018 – 2020 LC 500h 2018 – 2020 ES 350 2018 – 2020 LS 500 2017 – 2020 RX 350 2013 – 2015 LS 460 2018 – 2019 LS 500h 2018 – 2020 RX 350L 2017 GS 200t 2018 – 2019 NX 300 2014 – 2015 LX 570 2019 UX 200 2015 NX 200t 2018 – 2019 LX 570 2014 – 2015 GX 460 2014 IS-F 2018 – 2019 GX 460 The remedy for this campaign is being launched in phases. Confirm remedy eligibility on each VIN in TIS before starting any repairs. Update 7/1/2021: Technician qualifications to perform this recall have been updated Update 3/31/2021: 2018 – 2019 GX 460 models added 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 ELearning 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. 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 2 I. OPERATION FLOW CHART Verify Vehicle Eligibility 1. Confirm vehicle VIN matches the RO. 2. Check for Campaign eligibility using TIS. No further action required. Not Covered Covered Campaign complete. Return the vehicle to the customer. 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 Check the Campaign Status of the VIN to determine if Remedy is available Remedy 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 ..Remedy Not.. Available •I _ _____. I + t ♦ t t -~ 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 Available.. ..Remedy NOT 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. Campaign Description: Safe all 20LA01 (Remedy Notice), Multiple Campaign Status. ????????? Completion Status: Not Completed ,, ,, ,. I 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 • 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 Special Service Tools Cam Lock Retainer Jaws Handle 09808-01010 Or suitable 1/2” breaker bar Crossbar Used With Campaign Tools Retainer Ring Pliers These pliers were shipped to each dealership in early February 2021. 5 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. RETAINER TYPE 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) Special Notes: Campaign Tool: Cam Lock Retainer Jaws Requires use of the Handle from the Fuel Sender Lock Nut Wrench Kit, or a 1/2” breaker bar. Aftermarket alternative: CTA Tools 1044 Fuel Tank Lid Wrench 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) ES 350 (2019 & 2020) GX 460 RX 350/350L LC 500/500h GS 300/350 LX 570 LS 500/500h IS 200t/300/350 LS 460 RC 200t/300/350 IS-F UX 200 NX 200t / 300 6 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. 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: 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 wellventilated area and then disposed of as appropriate. 7 VI. COMPONENTS ES 350 2019 & 2020 (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 2019 & 2020 (VINs starting 58A) 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 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 *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 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. 10 GS 200t / 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. 11 GX 460 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 1 Yellow 15.2mm 4 Fuel Pump Gauge Retainer 1 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. 12 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. 13 IS-F 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 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. 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. 14 LS 460 / LS 460L 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 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. 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. 15 LC 500 / LC 500h LS 500 / LS 500h 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 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. 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. 16 LX 570 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 1 Yellow 15.2mm 4 FUEL PUMP GAUGE RETAINER 1 5 TUBE JOINT CLIP 16 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. 17 NX 200t 2015 NX 300 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 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 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. 18 NX 300 2019 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 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 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. 19 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. 20 RX 350 / RX 350L 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 1 Yellow 15.2mm 4 FUEL PUMP GAUGE RETAINER 1 5 FUEL TANK PIPE SETTING HOLDER 1 White 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. 21 UX 200 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. 22 VII. 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. 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. FUEL LEVEL RECOMMENDATIONS 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. 23 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: 24 REMOVAL TIP: CAM LOCK RETAINER (cont.) Lightly tighten the adjuster Fully tighten the 4 bolts 25 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 1. Using the pliers provided, release the adhesion between the Retaining Ring and the Fuel Tube Assembly around the entire circumference. 2. Using the SST, loosen the Retainer Ring. 26 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. REMOVAL TIP: TUBE ASSY REMOVAL 1) 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. 2) 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. 27 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 28 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: Repair Manual: Using a screwdriver (*a) with its tip wrapped in protective tape, remove the jet pump from the No. 1 fuel sub-tank. Tube still attached Jet pump properly removed from the No.1 fuel sub-tank. Replacement O-Ring will be installed in this location Example of Incorrect Disassembly: Tube incorrectly removed from jet pump Replacement O-ring is the incorrect size DO NOT disconnect the tube from the jet pump Replacement O-Ring is NOT provided for this location 29 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. 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. 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. Do not touch the electric circuit of the fuel sender gauge. Do not deform the arm of the fuel sender gauge. 30 DISASSEMBLY TIPS: O-RING REMOVAL During disassembly, the O-Ring may remain in the fuel pump housing. Be sure the 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 31 2. CLEAN SUB TANK ASSEMBLY a. Using brake cleaner, clean the sub-tank assembly. 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. 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. 32 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 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 33 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. Note: Fuel Pump O-Ring installation is critical to this repair. A visual inspection of the final assembly will confirm the correct installation. 34 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 35 X. INSTALL FUEL TUBE ASSEMBLY INSTALLATION TIP: PLASTIC RETAINER 36 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 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. 37 19 19 = 2019 20 = 2020 21 = 2021 22 = 2022 23 = 2023 Etc… Year Campaign is Launched 19TA01 T T = Toyota L = Lexus Vehicle Make A A = Safety Recall Remedy B = Safety Recall Interim C = Special Service Campaign D = Limited Service Campaign E = Customer Support Program F = Emissions Recall (May use other characters in unique cases) Field Action Category and Phase 01 01 = 1st Field Action of the year 02 = 2nd Field Action of the year 03 = 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 ◄ 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

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