Lexus Car ES, IS, LS 1998-06

Fuel Pump

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Removal & Installation



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel tank
     
    Fuel lines
     
    Fuel pump module locknut
     
    Fuel pump module
     

  6.  

To install:

  1. Install or connect the following:

    Fuel pump module with a new gasket. Rotate the module until the arrow is pointed toward the front of the vehicle, on all models except Grand Cherokee. The arrow must pointed toward the rear of the vehicle.
     
    Locknut. Torque the locknut to 55 ft. lbs. (74 Nm).
     
    Fuel lines
     
    Fuel tank
     
    Negative battery cable
     

  2.  
  3. Start the engine, check for leaks and repair if necessary.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. With the ignition switch in theLOCK
  6.  
  7. Remove or disconnect the following:

    Rear seat cushion
     
    Fuel pump connector
     
    Floor service hole cover
     

  8.  


NOTE
Do NOT lift the fuel pump assembly up using the wiring harness.



Fuel filler cap
 
Fuel outlet pipe and the return hose from the pump bracket
 
8 screws and lift out the pump/bracket assembly with gasket
 
Fuel pump lead wire
 
Lower end of the pump off the bracket
 
Fuel hose from the pump and remove the pump
 
Rubber cushion from the pump
 

To install:

  1. Install or connect the following:

    Filter and rubber cushion on the new pump
     
    Pump on the bracket
     
    Fuel hose and the wire connector on the pump
     
    Pump, using a new gasket and tighten the 8 screws to 35 inch lbs. (4 Nm)
     
    Fuel pipe and return hose to the pump and tighten the bolts to 22 ft. lbs. (29 Nm)
     
    Wire
     
    Service cover, and replace the rear seat
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  


    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump assembly-ES 300


  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable. Wait at least 90 seconds before performing any other work.
     
    Trunk floor mat
     
    Trunk trim cover
     
    Fuel pump electrical connector
     
    Rear seat bottom and seat back
     
    Partition cover
     
    Mounting bolts and remove the fuel pump set plate
     
    3 nuts and disconnect the fuel pump bracket from the tank
     
    Fuel hose from the bracket
     
    Pump, bracket and set plate as an assembly
     

  4.  

To install:

  1. Install or connect the following:

    A new gasket on the set plate
     
    Fuel hose to the pump and bracket
     
    Pump and bracket assembly with the 3 nuts; tighten the nuts to 48 inch lbs. (5 Nm). Install the set plate and tighten the bolts to 26 inch lbs. (3 Nm).
     
    Panel partition
     
    Rear seat cushion and back
     
    Fuel pump electrical connector
     
    Trim panel
     
    Spare tire and the trunk floor mat
     
    Negative battery cable
     

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

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable. Wait at least 90 seconds before performing any other work.
     
    Rear seat bottom and seat back
     
    Fuel pump tube
     
    8 bolts and fuel tank vent tube set plate
     
    Fuel pump and sensor gauge assembly
     
    Fuel suction hose and support
     
    Fuel pump cushion rubber
     
    Fuel pressure w/jet pump regulator assembly
     
    Fuel suction plate w/sender gauge
     
    Fuel pump and filter
     

  4.  

To install:

  1. To install, reverse the removal procedure. Install a new O-ring on the fuel jet pump regulator assembly and a new gasket on the fuel pump/sender gauge assembly. Torque the 8 bolts securing the fuel tank set plate to 52 in. lbs (6.0 Nm).
  2.  
  3. Inspect fuel pump operation and check for fuel leaks.
  4.  



Click image to see an enlarged view

Fig. Exploded view for fuel pump removal-ES 330

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable. Wait at least 90 seconds before performing any other work.
     
    Rear seat bottom and seat back
     
    Rear floor service hole cover
     
    Fuel suction w/pump and gauge tube assembly
     
    8 bolts and fuel tank vent tube set plate
     
    Vapor pressure sensor assembly
     
    Fuel suction hose and support
     
    Fuel pump cushion rubber
     
    Fuel sender gauge assembly
     
    Fuel suction plate w/sender gauge
     
    Fuel pump harness
     
    Fuel pump
     
    Fuel pump filter. Pry out clip and remove from pump
     
    Fuel pressure regulator assembly
     

  4.  

To install:

  1. To install, reverse the removal procedure. Install a new O-ring on the fuel suction w/pump and gauge assembly. Torque the 8 bolts securing the fuel tank set plate to 52 inch lbs. (6.0 Nm).
  2.  
  3. Inspect fuel pump operation and check for fuel leaks.
  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. With the ignition switch in the LOCK position, disconnect the negative battery terminal.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Do not lift the fuel pump assembly up using the wiring harness.



    Rear seat cushion
     
    Fuel pump connector
     
    Floor service hole cover
     



    Fuel filler cap
     
    Fuel outlet pipe and the return hose from the pump bracket
     
    8 screws and lift out the pump/bracket assembly with gasket
     
    Fuel pump lead wire
     
    Lower end of the pump off the bracket
     
    Fuel hose from the pump and remove the pump
     
    Rubber cushion from the pump
     

  8.  

To install:

  1. Install or connect the following:

    Filter and rubber cushion on the new pump
     
    Pump on the bracket
     
    Fuel hose and the wire connector on the pump
     
    Pump, using a new gasket and tighten the 8 screws to 35 inch lbs. (4 Nm).
     
    Fuel pipe and return hose to the pump and tighten the bolts to 22 ft. lbs. (29 Nm).
     
    Wire
     
    Service cover, and replace the rear seat.
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump assembly-ES300

  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable. Wait at least 90 seconds before performing any other work.
     
    Trunk floor mat
     
    Trunk trim cover
     
    Fuel pump electrical connector
     
    Rear seat bottom and seat back
     
    Partition cover
     
    Mounting bolts and remove the fuel pump set plate.
     
    3 nuts and disconnect the fuel pump bracket from the tank.
     
    Fuel hose from the bracket
     
    Pump, bracket and set plate as an assembly
     

  4.  

To install:

  1. Install or connect the following:

    A new gasket on the set plate
     
    Fuel hose to the pump and bracket
     
    Pump and bracket assembly with the 3 nuts; tighten the nuts to 48 inch lbs. (5 Nm). Install the set plate and tighten the bolts to 26 inch lbs. (3 Nm).
     
    Panel partition
     
    Rear seat cushion and back
     
    Fuel pump electrical connector
     
    Trim panel
     
    Spare tire and the trunk floor mat
     
    Negative battery cable
     

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

 
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