Mechanics

LEXUS LS 400 FUEL PUMP PROBLEM

1998 Lexus LS 400 • 300,000 miles

Where is access to fuel pump to replace it
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October 29, 2012.




CAUTION: Do not smoke or work near an open frame when working the fuel pump.

REMOVE NO. 1 REAR SEATS
REMOVE REAR DOOR SCUFF PLATES, STEP PLATES AND REAR SEAT LOCK COVERS
REMOVE FLOOR SERVICE HOLE COVER

(a) Take off the front and rear floor carpets.
(b) Remove the 2 screws and service hole cover.

DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
DISCONNECT FUEL MAIN TUBE AND RETURN TUBE (FUEL TUBE CONNECTORS) FROM FUEL SUCTION PLATE

CAUTION: Perform disconnecting operation of the fuel tube connector (quick type) after observing precaution.
As there is retained pressure in the fuel line, prevent it from splashing inside the vehicle compartment.
As the quick connector seals tube and suction plate through O-rings, perform the operation while taking sufficient care not to damage the contact surface or let the foreign matter stick on it.
Be sure to perform the disconnection with your hands. Do not use tools.
Do not bend or turn the nylon tube forcefully.

(a) Before operation, remove the foreign matter or dirt stick to the tube joint clips and clean them.

(b) Enlarge the tip of the clips with your finger and pull them out for disconnection.

(c) Pull out the fuel main tube and return tube.
If the nylon tube and suction plate stick together, ease the connection by turning the nylon tube with your hand and pull it out for disconnection.

NOTICE: Plug the port of the fuel suction plate with a clean rubber cap.

(d) After disconnection, protect the connector with a vinyl bag.

REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY FROM FUEL TANK

(a) Remove the 8 bolts.
(b) Pull out the fuel pump and sender gauge assembly.

NOTICE: Do not damage the fuel pump filter.
Be careful that the arm of the sender gauge should not bent.

(c) Remove the gasket from the fuel section plate.

REMOVE LEAD WIRE FROM FUEL PUMP
REMOVE FUEL PUMP FROM FUEL PUMP BRACKET

(a) Pull out the lower side of the fuel pump from the pump bracket.
(b) Disconnect the fuel hose from the fuel pump and remove the fuel pump.
(c) Remove the rubber cushion from the fuel pump.

REMOVE FUEL PUMP FILTER FROM FUEL PUMP

(a) Using a small screwdriver, remove the clip.
(b) Pull out the pump filter.

INSTALLATION

INSTALL FUEL PUMP FILTER TO FUEL PUMP Install the pump filter with a new clip.
INSTALL FUEL PUMP TO FUEL PUMP BRACKET

(a) Install the rubber cushion to the fuel pump.
(b) Connect the fuel hose to the outlet port of the fuel pump.

(c) Install the fuel pump by pushing the lower side of the fuel pump.

INSTALL LEAD WIRE TO FUEL PUMP
INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY TO FUEL TANK

(a) Install a new gasket to the fuel suction plate.
(b) Insert the fuel pump and sender gauge assembly into the fuel tank.

(c) Install the fuel tank vent tube set plate with the 8 bolts.

Torque: 3.5 N.M (35 kgf. Cm, 31 in. Lbf)

CONNECT FUEL MAIN TUBE AND RETURN TUBE (FUEL TUBE CONNECTORS) TO FUEL SUCTION PLATE

(a) Before installing the tube connectors, check to see the connection between the nylon tube and suction plate for the presence of foreign matters.

(b) Attach the fuel tube connectors to the ports of the fuel suction plate and insert the clips until you hear a click.

(c) After connection, pull out the clips to check to see that they are installed securely.

CONNECT FUEL PUMP & SENDER GAUGE CONNECTOR
CHECK FOR FUEL LEAKS
INSTALL FLOOR SERVICE HOLE COVER

(a) Install the service hole cover with the 2 screws.
(b) Cover the rear and front floor carpets.

INSTALL REAR DOOR SCUFF PLATES, STEP PLATES AND REAR SEAT LOCK COVERS
INSTALL NO. 1 REAR SEATS

ASEMaster6371
Oct 29, 2012.


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