TECHNICAL INSTRUCTIONS
FOR
SPECIAL SERVICE CAMPAIGN FLF
FUEL PUMP REPLACEMENT
CERTAIN 2010 – 2012 MODEL YEAR HS 250h

Updated 1/27/16
- The fuel tank gasket kit part number has been corrected.

The repair quality of covered vehicles is extremely important to Lexus. All dealership technicians performing this
SSC 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 SSC repair 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

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.

Verify Vehicle Eligibility
1. Check the TIS Vehicle Inquiry
System.

Not Involved

No further action required.
Release vehicle

Invoved
Replace the fuel pump and install the
additional wiring harness.

Campaign complete.

Video Supplement: Click here to watch an overview of the repair

2

II. BACKGROUND

The subject vehicles are equipped with a fuel pump that could experience premature wear of internal
components, causing it to become inoperative. If this occurs the vehicle will illuminate various warning
lamps and enter a fail-safe mode, reducing motive power.

III. IDENTIFICATION OF AFFECTED VEHICLES
A. COVERED VIN RANGE
•
•

Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Special Service Campaign,
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.

3

IV. PREPARATION
A. PARTS
Part Number
04005-33275

Part Number
04004-85552

Part Description
Fuel Pump Kit*
*The kit includes the following components

Quantity
1

Part Description (Kit Contents)
Fuel Pump
Fuel Pump Harness
Tie-Wrap
Junction Block Harness
Fuel Pump O-Ring

Quantity
1
1
3
1
1

Part Description
Fuel Tank Gasket Kit**
**The kit includes the following components

Quantity
1

Part Description (Kit Contents)
Fuel Tank Gasket
Fuel Pump Gauge Retainer Ring (White)

Quantity
1
1

B. MATERIALS
• Protective Tape
C. TOOLS & EQUIPMENT
•
•

•

Techstream
•
Standard Hand Tools

Part Number
09808-01030*

Butyl Tape

•

Plastic Bags

Vernier Caliper

•
•

Tray
Marker Pen

Part Name
Plate*
Claw set to remove retaining ring**

Quantity
1
4

Adaptor for plate**

1

Retainer Pliers**

1

*This tool is a component of SST kit 09808-14030 (Essential tool)
** These tools where supplied to the dealer prior to the start of the campaign

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V. SAFETY PRECAUTIONS
CRITICAL INFORMATION – READ THOROUGHLY
These cautions should be observed when performing this campaign. Failure to follow these cautions
could result in damaged parts or inadequate repair quality.
1. VENTILATION
a) Preform this repair in a well-ventilated area.
b) DO NOT have any electrical devises operating in the area
that could generate a spark.
c) Any spilled fuel should be cleaned up immediately and clean
up material should be disposed of in accordance with local
and state regulations.

2. DIFFUSE FUEL VAPOR
a) Periodically use compressed air to clear the area of fuel
vapor build up.

3. PERSONAL PROTECTION
a) Gasoline emits vapors that could cause physical illness. Use
an appropriately rated gas mask when needed.
b) Wear protective eye wear when performing this repair.

4.
a)
b)
c)

FIRE PREVENTION
Ensure that there are working fire extinguishers nearby.
Ensure that there are no open flames in the area.
Be aware of static electricity.

5. DO NOT ALLOW FUEL TO COME INTO CONTACT WITH
INTERIOR COMPONENTS

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VI. COMPONENTS

6

7

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VII. VEHICLE PREPARATION
This campaign only covers the replacement of the fuel pump.
No other components in the engine management system are covered under this campaign.

1. OPEN ALL 4 WINDOWS
a) Lower all 4 windows to prevent fuel vapor from
condensing in the vehicle.

2. REMOVE THE REAR SEAT CUSHION
a) Disengage the 2 front hooks for the seat cushion as
shown.
b) Disengage the 2 guides from the seatback.
c) Remove the seat cushion from the vehicle and store in an
area where it will not be damaged.
If the plastic locks for the front hooks
come out of the floor pan they will need
to be replaced.

3. CHECK FUEL LEVEL
a) Check and record fuel level to ensure correct sender
operation after pump replacement.
NOTE: DO NOT remove the pump assembly if the fuel
level is ¾ of a tank or higher. If the fuel level is ¾
or higher the tank will need to be drained refer to
the appendix section.

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4. CHECK FOR DTC’S
a) Using Techstream, perform a health check to confirm if there
are any DTCs present in the system (current, history or
pending).
b) Record and clear any codes.

5. DISCHARGE THE FUEL SYSTEM
a) Remove the fuel filler cap to relieve pressure in the tank.
b) Remove the fuel service cover.

c)
d)
e)
f)
g)
h)

Disconnect the fuel pump connector.
Using Techstream place the vehicle in “inspection mode”
Start the engine and allow it to run until it stops on its own.
Shut the vehicle “OFF”.
Crank the engine again and ensure it does not start.
Shut the vehicle “OFF”.

NOTE: DTC P0171/25 may be set during this procedure.

6. POWER DOWN VEHICLE
a) Move both front seats and backrests fully forward.
b) Remove the luggage floor mat.
c) Open the luggage compartment trim cover on the right
side of the vehicle.
d) Disconnect the negative battery cable.
NOTE: After the start switch has been turned “OFF” allow
at least 6 minutes before disconnecting the
battery to allow for systems to power down.

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VIII. INSTALL ADDITIONAL WIRE HARNESS Video

1. REMOVE THE LF DOOR SCUFF PLATE
a) Disengage the 7 claws and 4 clips.
b) Remove scuff plate.

2. REMOVE THE LEFT COWL TRIM BOARD
a) Remove the plastic nut.
b) Disengage the claw and the clip.
c) Remove the trim board.

3. INSTALL THE NEW HARNESS
a) Disconnect the 4 connectors from the junction block.
NOTE: All 4 connectors must be disconnected to allow
the correct routing of the new harness.

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b) Remove the tape from the harness as shown.
NOTE: Remove the tape by hand. Cutting the tape
could damage the harness.

c) Connect the connector of the new harness to the
connector of the disconnected harness.

d) Connect the connector of the new harness to the
junction block.

e) Tie-wrap the connector for the new harness as shown below.
NOTE: Ensure to position the tie wrap lock as shown to prevent damage to surrounding
components

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f)

Reconnect the 3 connectors.

g) Detach the 2 claws for the harness clamp.

h) Route the harness on top of the existing floor harness.

i)

Tie-wrap the new harness as shown below approximately 15mm from the clamp.
NOTE: Ensure to position the tie wrap lock as shown to prevent damage to surrounding
components

NOTE: The design of the new harness allows the
wiring inside to conform around the floor
harness.

13

j)

While pressing down on the new harness reengage
the 2 harness clamps.
NOTE: Ensure that the new harness conforms
around the floor harness so that the clamp engage
properly.

k) Tie-wrap the new harness to the floor harness as shown below 20-30mm from the floor harness protector.
NOTE: Ensure to position the tie wrap lock as shown to prevent damage to surrounding
components

IX. REPLACE THE FUEL PUMP
1. CLEAN THE AREA AROUND THE RETAINING
RING
a) Clean the area around the retaining ring and
fuel line with a vacuum prior to removing the
fuel pump so no foreign matter enters the fuel
tank.
NOTE: DO NOT use an air gun as it will
circulate dust inside the vehicle.
If the fuel level is above ¾ of a tank it
will need to be drained refer to the
appendix.

Video

14

2. APPLY TAPE
a) Apply protective tape around the
circumference of the service port as shown.
The area surrounding the service
port could be sharp.

3. DISCONNECT THE FUEL LINE
a) Place cloth around the fuel line to catch any
fuel that could be released due to residual
pressure in the tank.
NOTE: Wear the appropriate protective
equipment when disconnecting the
fuel line. There could be up to 100 cc’s
of fuel in the line under residual
pressure.

b) Disengage the clip from the fuel tube using a
thin screwdriver while disengaging the claws
with your finger.
Remove the fuel line by hand
using tools could damage the line.
If the line is stuck push and pull
on the line to release.

15

c) Place the open end of the fuel line into a
plastic bag and secure.

d) Secure the fuel line away from the retaining
ring.

e) Tape the fuel line under the floor as shown.
NOTE: It may be necessary to clean the area if
the tape does not adhere to the floor.

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f)

Place absorbent material around the service
port as shown.

g) Place a reference mark on the fuel pump assembly and the floor as shown.
NOTE: The top of the fuel pump assembly has 2 tabs that engage the fuel tank.
The reference mark ensures that the fuel pump assembly will be reinstalled in the correct
position.

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h) Place two reference marks on the floor as shown.
NOTE: Reference marks are need for reinstallation.

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4.

RELEASING THE BOND BETWEEN THE FUEL PUMP ASSEMBLY AND RETAINING RING
a) Using the pliers provided, release the adhesion between the retaining ring and the top of the fuel pump
assembly.
NOTE: Ensure that you release the adhesions all the way around the retaining ring.
DO NOT try to remove the retaining ring prior to releasing the bond, due to the high
torque required to remove the ring the tank could be damaged.

19

20

5. REMOVE THE RETAINING RING
a) Ensure that the fuel line is secured and out of
the way.

b) Place the 4 supplied claws evenly around the
circumference of the retaining ring as shown.

21

NOTE: Ensure the claw engages the retaining
ring as shown.
The claws may need to be tilted to
engage the ring.
DO NOT loosen or tighten the hex bolt
on the claws.
DO NOT use any other tool to remove or
install the retaining ring.

c) Install the SST plate to engage 2 of the claws
as shown.
SST: Component of SST kit 09808-14030
d) Loosely install the 2 round plates and bolts.
NOTE: Ensure the round plates are properly
installed into the SST.

e) Loosely install the other 2 round plates and
bolts.
NOTE: The claws may need to be tilted.

22

f)

Ensure that the center of the SST plate is
centered on the fuel pump assembly.
NOTE: Ensure that the round plates are
correctly engaged into the SST
plate.

g) Tighten the 4 bolts that attach the claws to
the SST plate.
NOTE: Ensure that the claws are
perpendicular to the SST plate.

h) Insert the supplied attachment into the SST
plate.
NOTE: Using a 19mm 12 point socket will
allow more angles for the drive
handle.

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i) Slowly loosen the ring 90 degrees.
NOTE: DO NOT press down or tilt the SST as
this could damage components.
If the ring does not come loose repeat
releasing the bond between the ring
and fuel pump assembly.

Note the following cautions while loosening the ring:
•
•

A spring inside the fuel pump
assembly will exert upward force on
the ring.
To prevent damaging components
ensure that the top of the fuel pump
assembly is fully engaged into the fuel
tank when rotating the retention ring.

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j)

While another worker holds the top of the fuel pump assembly down slowly turn the retaining ring until the
ring disengages from the threads.
NOTE: Ensure the reference marks say aligned.
The ring needs to be turned approximately 1 ½ turns to disengage the threads.

k) Remove the retaining ring and SST.
l) Separate the ring from the SST.

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6. REMOVE FUEL PUMP ASSEMBLY
a) Place a container next to the service hole for
the fuel pump assembly to be placed into.
NOTE: Ensure the container is large enough