Lexus Car ES, IS, LS 1998-06

Removal & Installation

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NOTE
The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module . The fuel pump module is located within the fuel tank.

  1. Remove fuel tank.
  2.  
  3. Remove fuel pump module.
  4.  
  5. Remove electrical wire connector at sending unit terminals.
  6.  
  7. Press upward on release tab to remove sending unit from pump module.

    Click image to see an enlarged view

    Fig. The location of the fuel level sending unit for the Cherokee



    Click image to see an enlarged view

    Fig. The location of the fuel level sending unit for the Grand Cherokee

  8.  

To install:

  1. Position sending unit to pump module and snap into place.
  2.  
  3. Connect electrical connector to terminals.
  4.  
  5. Install fuel pump module.
  6.  
  7. Install fuel tank.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work
  6.  
  7. Remove the fuel pump and sending gauge assembly.
  8.  
  9. Unlock the sender gauge assembly, and move it downward to remove.
  10.  

To install:

  1. Install the fuel sender gauge assembly by pushing it upward to lock into place.
    NOTE
    By pushing the sender gauge downward, confirm that it is certainly locked.

  2.  
  3. Install the fuel pump and sending gauge assembly.
  4.  
  5. Connect the negative battery cable.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work
  6.  
  7. Remove the fuel pump and sending gauge assembly.
  8.  
  9. Remove the fuel sending gauge from the fuel pump assembly as follows:


    1. Disconnect the fuel sender gauge connector.
    2.  
    3. Using a screwdriver with the tip wrapped in tape, unfasten the clamp to release the fuel sender gauge. Then slide the fuel sender gauge to remove it from the fuel pump.
    4.  

  10.  

To install:

  1. Install the fuel sending gauge to the fuel pump assembly as follows:


    1. Slide the fuel sender gauge to install it onto the fuel pump assembly and engage the clamp.
    2.  
    3. Connect the fuel sender gauge connector.
    4.  

  2.  
  3. Install the fuel pump and sending gauge assembly.
  4.  
  5. Connect the negative battery cable.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work
  6.  
  7. Remove the fuel pump and sending gauge assembly.
  8.  
  9. Separate the fuel sending gauge from the fuel pump, fuel filter, fuel pressure regulator and fuel return jet tube assembly.
  10.  

To install:

  1. Install the fuel filter, fuel pressure regulator and fuel return jet tube assembly to the fuel sending gauge assembly.
  2.  
  3. Install the fuel pump and sending gauge assembly.
  4.  
  5. Connect the negative battery cable.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work
  6.  
  7. Remove the fuel pump and sending gauge assembly.

    Click image to see an enlarged view

    Fig. Press down on the sender gauge claw (A), then slide the sender gauge upward.-IS 250 and IS 350

  8.  
  9. Remove the fuel sending gauge from the fuel pump assembly as follows:


    1. Disconnect the fuel sender gauge connector.
    2.  
    3. Press down on the sender gauge claw. Then slide the sender gauge upward.
    4.  

  10.  

To install:

  1. Install the fuel sending gauge to the fuel pump assembly as follows:


    1. Set the fuel sender gauge to the No. 1 fuel sub-tank. Then slide the sender gauge downward to install it.
    2.  
    3. Connect the fuel sender gauge connector.
    4.  

  2.  
  3. Install the fuel pump and sending gauge assembly.
  4.  
  5. Connect the negative battery cable.
  6.  



Click image to see an enlarged view

Fig. Fuel sender gauge assembly.-LS 400

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work
  6.  
  7. Remove or disconnect the following:

    Trunk floor mat
     
    Trunk trim cover
     
    Fuel sender gauge electrical connector
     
    6 mounting bolts and remove the fuel sender gauge assembly and gasket from the fuel tank
     

  8.  

To install:

  1. Install or connect the following:

    Fuel sender gauge assembly with a new gasket into the fuel tank and tighten the 6 mounting bolts to 31 inch lbs. (3.5 Nm).
     
    Fuel sender gauge electrical connector
     
    Trunk trim cover
     
    Trunk floor mat
     
    Negative battery cable
     

  2.  
  3. Start the engine; check the fuel system for leaks.
  4.  

 
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