Lexus GX470 2003-06

Fuel Pump

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Removal & Installation



  1. Disconnect the battery ground.
  2.  
  3. Remove the rear seat.
  4.  
  5. Remove the rear floor step cover.
  6.  
  7. Remove the left quarter scuff plate.
  8.  
  9. Remove the service hole cover.
  10.  
  11. Disconnect the wiring.
  12.  
  13. Remove the filler hose.
  14.  
  15. Drain the fuel.
  16.  
  17. Remove the skid plate.
  18.  
  19. Disconnect the fuel lines.
  20.  
  21. Disconnect the breather hose.
  22.  
  23. Disconnect the vent hose.
  24.  
  25. Remove the fuel tank.
  26.  
  27. Disconnect the supply and return lines.
  28.  
  29. Unscrew the lockring, using a tool such as SST09808-14020.
  30.  
  31. Remove the pump module from the tank.
  32.  
  33. Installation is the reverse of removal. Make sure that all fuel fittings are secure. Use a new gasket and new lockring. Start the lockring and make a reference mark before turning it. Turn the locking 1 full turn by hand. Using the SST, turn the lockring one more full turn. And position the mark on the locking as shown.
  34.  


    Click image to see an enlarged view

    Fig. Position the lockring marks as shown-GX470



    Click image to see an enlarged view

    Fig. Fuel tank and related parts-GX470




Click image to see an enlarged view

Fig. Exploded view of the fuel pump and related components

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel tank
     
    Fuel pump harness connector
     
    Fuel lines
     
    Fuel pump module
     

  6.  

To install:

  1. Install or connect the following:

    Fuel pump module. Tighten the bolts to 35 inch lbs. (4 Nm).
     
    Fuel lines
     
    Fuel pump harness connector
     
    Fuel tank
     
    Negative battery cable
     

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

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the spare tire.
  6.  
  7. Disconnect the fuel pump connector and remove the fuel tank protector.
  8.  
  9. Disconnect the main and fuel return tubes.
  10.  
  11. Disconnect the fuel tank vent hose.
  12.  
  13. Disconnect the inlet and breather hoses.
  14.  
  15. Support the fuel tank with a jack, loosen the tank strap bolts remove the straps and lower the tank.
  16.  
  17. Disconnect any necessary hoses and wiring from the pump.
  18.  
  19. Using the tool illustrated, loosen the pump retainer.
  20.  
  21. Remove the pump and gasket.

    Click image to see an enlarged view

    Fig. Use the tool illustrated to remove the fuel pump retainer-2005-06 GX470

  22.  

To install:

  1. Install a new gasket and the pump. Make sure to align the keyway of the suction tube with the key of the suction plate No. 1.
  2.  
  3. Apply a multipurpose grease to the whole surface of the pump retainer.
  4.  
  5. Align the triangle mark on the new pump retainer with the S mark on the tank while pushing the suction tube down and attach the gauge retainer.
  6.  
  7. Using the same tool used to remove the pump retainer, tighten the retainer 1 1 / 2 times. The triangle mark on the pump should be positioned between the A and MAX marks on the tank.
  8.  
  9. Attach any electrical connections and hoses.
  10.  
  11. Install the fuel tank and tighten the strap bolts to 45 ft. lbs. (62 Nm).
  12.  
  13. Install the remaining components.

    Click image to see an enlarged view

    Fig. Align the triangle mark on the new pump retainer with the S mark on the tank-2005-06 GX470



    Click image to see an enlarged view

    Fig. The triangle mark on the pump should be positioned between the A and MAX marks on the tank when properly tightened

  14.  

 
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