TECHNICAL INSTRUCTIONS
FOR
SPECIAL SERVICE CAMPAIGN GLE
FUEL TANK RING REPLACEMENT
CERTAIN 2016 MODEL YEAR RX450h

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 E-Learning course “Safety
Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly;
technicians performing this repair must successfully complete E-Learning LSCFLE AND are required to
currently hold at least one of the following certification levels:





Senior Service Technician
Senior Diagnostic Specialist
Master Service Technician
Master Diagnostic Specialist

It is the dealership’s responsibility to select technicians with the above certification level or greater 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.

I.

OPERATION FLOW CHART

The flow chart is for reference only. DO NOT use it in place of the full technical instructions. Follow ALL steps
as outlined in the full technical instructions to confirm the campaign is completed correctly.

Check the TIS Vehicle Inquiry System.

Not Covered

No further action required.

Covered
Replace the fuel tank vent tube set
plate.

Campaign Complete

II. BACKGROUND
In the subject vehicles the fuel level float arm in the fuel tank may become obstructed and cause the fuel level gauge
to display an inaccurate reading. This could result in the vehicle running out of fuel during operation. If this occurs,
the vehicle may illuminate the check engine light and enter EV fail-safe mode.

2

III. IDENTIFICATION OF AFFECTED VEHICLES



Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Safety Recall, and that the
campaign has not already been completed prior to dealer shipment or by another dealer.
TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or
were completed by another dealer.

IV. PREPARATION
A. PARTS
All applicable vehicles will require the parts in the table below
Part Number
Description
77168-48010
PLATE, FUEL TANK VENT TUBE SET
77169-33030
GASKET, FUEL SUCTION TUBE SET
17451-0D140
GASKET, EXHAUST PIPE

B. MATERIALS
 Vinyl Hose
 Marker Pen

Qty
1
1
2

 Plastic Bag

C. TOOLS & EQUIPMENT



Standard hand tools
Transmission Jack




Torque wrench
Techstream

3

V. FUEL TANK VENT TUBE SET PLATE REPLACEMENT
A. COMPONENTS

4

COMPONENTS CONTINUED…

5

B. CONFIRM FUEL TANK
1. CONFIRM IF THE FUEL TANK WAS PREVIOUSLY REPLACED
a) In TIS confirm if the vehicle had the fuel tank previously replaced with part number 77001-0E111.
Previously Replaced with 77001-0E111: No Further Action Required
Vehicle Equipped with Original Tank: Continue with to Step C.
While the majority of vehicles will have the original fuel tank installed, there is a chance a small
number of vehicles could have a countermeasure fuel tank previously installed. DO NOT replace
the set plate on a counter measured tank, installation of the set plate on the counter measured
tank will cause additional stress to be placed on the fuel pump wire harness and fuel lines.

C. FUEL TANK REMOVAL
1. CONFIRM FUEL LEVEL
Note: If the fuel tank is full syphon fuel from tank.
2. DEPRESSURIZE FUEL SYSTEM
Depressurize Fuel System 2016 RX450h

6

3. DISCONNECT THE BATTERY
a) Remove the deck board assembly.
b) Remove the rear deck floor box.

c) Disconnect the battery.
Wait at least 90 seconds after disconnecting the
battery.

4. REMOVE THE CENTER EXHAUST PIPE ASSEMBLY
a) Remove the 2 bolts and compression springs connecting the
center pipe to the tail pipe.
b) Remove the 2 bolts and compression springs connecting the
center pipe to the exhaust manifold.
c) Remove the 4 exhaust pipe supports.
d) Remove the center exhaust pipe and gaskets.

5. REMOVE THE FRONT CENTER FLOOR COVER
a) Remove the clip (A).
b) Remove the 2 screws and 4 bolts.
c) Disengage the 2 clips (B) and remove the cover.

7

6. REMOVE THE NO. 3 FRONT FLOOR HEAT INSULATOR
a) Remove the 4 nuts and floor insulator from the vehicle body.

7. REMOVE THE NO. 1 FUEL TANK PROTECTOR
a) Remove the screw.
b) Disengage the 4 grommets and remove the fuel tank protector.

8. DISCONNECT FUEL TANK VENT HOSE
a) Disengage the clamp and disconnect the fuel tank vent hose from
the charcoal canister.

9. DISCONNECT FUEL TANK MAIN TUBE ASSEMBLY
a) Disengage the clamps and disconnect the fuel tubes from the
fuel lines.

8

10.

DISCONNECT FUEL TANK WIRE HARNESS

a) Disconnect the clamp and disconnect the two wire harness
connectors.

11.

DISCONNECT NO. 3 FUEL TANK BREATHER TUBE

12. DISCONNECT FUEL TANK FILLER PIPE HOSE
a) Pull out the retainer (a) to disengage the lock claw (b).
b) Pull off the fuel tank filler pipe hose from the tank.

13. REMOVE FUEL TANK
Using a trans jack or engine hoist support the fuekl tank.

c) Remove the 4 bolts and remove the fuel tank straps.
d) Carefully lower the fuel tank.

9

D. FUEL TANK VENT TUBE SET RING REMOVAL
1. MARK THE OLD FUEL TANK SET RING AND CLEAN TOP OF
FUEL TANK
a) Clean off the top of the fuel tank to ensure no dirt and debris
falls into the tank.
b) Mark the set ring before removal to ensure it does not get
reused.
The new set ring has a different offset, ensure to
mark the old one so that it is not reused.
2. DISCONNECT TUBES AND WIRE HARNESS CONNECTORS.
a) Disconnect the fuel pump and fuel pressure sensor electrical
connectors.
b) Remove the fuel tube joint clips and remove the fuel tubes.

3. REMOVE SET RING BOLTS
a) Remove the 8 set ring bolts and store them in a safe location
for reuse.

E. FUEL TANK VENT TUBE SET RING REPLACEMENT
1. REPLACE FUEL SUCTION TUBE SET GASKET
a) Carefully remove the fuel pump and sending unit assembly from
the fuel tank.
Use caution when removing to ensure the sending
unit arm does not get bent.
b) Remove gasket from the suction tube set and gauge assembly
and store in a separate location so it will not be reused.
c) Install a NEW gasket onto the suction tube set and gauge
assembly.
d) Reinstall the suction tube set and gauge assembly into the tank.

10

2. INSTALL NEW FUEL TANK VENT TUBE SET PLATE
a) Confirm that the letter “F” is tamped into the set plate.
b) Confirm that the alignment of the fuel pump matches the NEW
set plate.

c) Install the NEW fuel tank vent tube set plate with the 8 bolts.
Torque Spec: 53in-lbs (61kgf-cm, 6.0Nm)

3. RECONNECT FUEL TUBES AND ELECTRICAL CONNECTORS
a) Push the fuel tube joint onto the tube plug of the suction plate
sub assembly and then install the fuel tube joint clip.
b) Reconnect the fuel pump and fuel tank pressure sensor
electrical connectors.
If the fuel tubes and wire harness connectors are
difficult to install due to insufficient slack, this is an
indication that the fuel tank was previously replaced.
Confirm on TIS if the tank was previously replaced.
F. FUEL TANK REINSTALLATION
1. RAISE FUEL TANK USING TRANS JACK OR ENGINE LIFT

2. REINSTALL THE FUEL TANK STRAPS
a) Align the fuel tank into the proper position on the vehicle.
b) Reinstall the fuel tank straps.
Torque Spec: 29ft-lbs (400kgf-cm, 39.0Nm)

11

3. REINSTALL THE FUEL TANK FILLER PIPER HOSE
a) Push the fuel tank filler pipe hose onto the fuel tank.
b) Push the retainer in to engage the 2 claws.
c) Confirm that the filler pipe is securely installed.

4. REINSTALL THE NO. 3 FUEL TANK BREATHER TUBE
a) Reconnect the breather tube and confirm it is securely installed.

5. RECONNECT FUEL TANK MAIN TUBE ASSEMBLY

6. RECONNECT FUEL TANK WIRE HARNESS
a) Reconnect the two wire harness connectors and secure the
clamp.

7. DISCONNECT FUEL TANK VENT HOSE
a) Reconnect the fuel tank vent hose to the charcoal canister and
secure with the clamp.

12

8. REINSTALL THE NO. 1 FUEL TANK PROTECTOR
a) Reengage the 4 grommets.
b) Reinstall the screw.

9. REINSTALL THE NO. 3 FRONT FLOOR HEAT INSULATOR
a) Reinstall the 4 nuts and floor insulator from the vehicle body.
Torque Spec: 43in-lbs (50kgf-cm, 4.9Nm)

10. REINSTALL THE FRONT CENTER FLOOR COVER
a) Reinstall the cover and two screws and 4 bolts.
b) Reinstall the cover and reengage the 2 clips (B).
c) Reinstall clip (A).

11. REINSTALL THE CENTER EXHAUST PIPE ASSEMBLY
a) Measure the free length of the exhaust compression springs.
OK Reuse: Spring length is 41.5 mm or greater
Replace: Spring length is less than 41.5 mm
b) Temporarily install the NEW exhaust gaskets using a plastic
hammer and wood block.

13

c) Rehang the center exhaust pipe assembly by connecting it to
the 4 exhaust supports.
d) Reinstall the exhaust pipe to the exhaust manifold by installing
the two compression springs and bolts.
e) Reinstall the center exhaust pipe assembly to the tail pipe by
reinstalling the 2 compression springs and bolts.
Torque Spec: 32ft-lbs (438kgf-cm, 43Nm)
Note: Torque the bolts in multiple steps to ensure the
exhaust gasket is crushed evenly.
f)

Check the space between the flanges to ensure the gasket has
been crushed evenly.
*1

Center Exhaust Pipe Assembly (TWC: Rear
Catalyst)

*2 Tail Exhaust Pipe Assembly
*3 Exhaust Pipe Gasket
*a Space between Flanges: 8.5 mm (0.335 in.
12. RECONNECT BATTERY

13. REINSTALL REAR DECK FLOOR BOX
a) Reinstall the rear deck floor box and install the 3 clips.
b) Reinstall the deck board assembly.

14. START VEHICLE AND CHECK FOR FUEL LEAK
15. PERFORM EVAP SYSTEM CHECK

◄ VERIFY REPAIR QUALITY ►
−
−
−
−

Confirm fuel tank vent tube set ring was installed
Confirm there are no fuel leaks
Confirm no EVAP leaks
Confirm removed fuel is returned to vehicle
If you have any questions regarding this update, please contact your area representative.

14