TECHNICAL INSTRUCTIONS
FOR
SPECIAL SERVICE CAMPAIGN 25LC01
LOW-PRESSURE FUEL PUMP

CERTAIN 2019 ES 300h VEHICLES

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 are required to have completed the following
course.
• LIC206A - Electrical Repair 1
It is the dealership’s responsibility to select technicians that have completed the
above courses 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.

Submitted to NHTSA on 05/07/2025

I.

OPERATION FLOW CHART

2
Submitted to NHTSA on 05/07/2025

II. IDENTIFICATION OF AFFECTED VEHICLES
1. CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY
a. Compare the vehicle’s VIN to the VIN listed on the Repair Order to ensure they match.
b. Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Campaign, and
that it has not already been completed.
Note: TMNA warranty will not reimburse dealers for repairs completed on vehicles that are not
affected or were previously completed, even by another dealer.

III. PREPARATION
A. PARTS
Model
ES 300h
(VIN begins with JTH)

Part #
04009-86325
04009-80747

Qty
1
1

Description
KIT, PUMP, FUEL
REPLACEMENT KIT, FUEL PUMP

Warranty will only reimburse dealers for the part numbers listed. Any other part numbers will not be
accepted on the campaign claim.
B. TOOLS & EQUIPMENT
•
•
•
•

Standard Hand Tools
Torque Wrench
Air Blow Gun
Gas Caddy (minimum 25-gallon capacity)

C. MATERIALS
• Brake Cleaner

3
Submitted to NHTSA on 05/07/2025

D. SPECIAL SERVICE TOOLS
The ES 300h uses a cam lock retainer type for the fuel pump assembly in the fuel tank.
Cam Lock
Type:
SST

Option 1
SST
Sender Lock Nut Wrench Kit (09808-14031)
Claw: 105mm Jaw Set (09808-01070)
Crossbar (09808-01030)
Campaign Tool:
Cam Lock Retainer Jaws

Option 2
Campaign Tool
(improved design over
SST)

Requires use of the Handle from the Fuel Sender Lock Nut
Wrench Kit, or a 1/2” breaker bar.

4
Submitted to NHTSA on 05/07/2025

IV. BACKGROUND
The subject vehicles are equipped with a low-pressure fuel pump which may stop operating. If this
were to occur, warning lights and messages may be displayed on the instrument panel, and the
engine may run rough. This will lead to the vehicle entering a failsafe driving mode in which the
vehicle can still be driven for certain distances.

V.

SAFETY PRECAUTIONS

CAUTION:
 When installing/uninstalling the fuel system components, keep safety first in mind and
carefully observe the following instructions to avoid accidents:
a. When working on the fuel system, display a Flammable - Keep Fire Away sign.
b. Smoking is prohibited nearby.
c. Perform this work in an area where there are no sparks nearby from the operation of welders,
grinders, drills, electric motors, stoves, etc.
d. DO NOT use electrical devices nearby because they can become hot and the operation of
power switches can generate sparks.
5
Submitted to NHTSA on 05/07/2025

e. DO NOT use iron or steel hammers while working, because they may generate sparks.
f. DO NOT start engines even in adjacent stalls.
g. Prepare fire extinguishers before starting any work.
h. Perform this work in a well-ventilated area (natural ventilation). DO NOT use exhaust fans or
electric fans, because their motors might generate sparks.
i. Since it is possible for fuel vapor to build up, DO NOT work in or near a pit.
j. If fuel is spilled, use shop towels or similar material to quickly wipe it up and then use
compressed air to diffuse the fuel vapor.
k. Shop towels and other materials that have come into contact with fuel should be dried in a wellventilated area and then disposed of as appropriate.

6
Submitted to NHTSA on 05/07/2025

VI.

COMPONENTS
ES 300h
(VIN begins with JTH)

Replacement items in red

No.

Part #

Qty

1

0400986325

1

Contents of Part Kit

Qty

Tape
Color

FUEL PUMP

1

2

FUEL SUCTION TUBE SET
GASKET

1

3

O-RING

2

4

REAR SEAT CUSHION LOCK
HOOK

2

O-RING

1

RED

6

O-RING

1

GREEN

7

FUEL TANK PIPE SETTING
HOLDER

1

WHITE

5

0400980747

1

GOLD

Remarks

Dispose of 1 oring
Dispose (Not
used)
Dispose (Not
used)
Dispose (Not
used)

Warranty will only reimburse dealers for the part numbers listed. Any other part numbers will not be
accepted on the campaign claim.

7
Submitted to NHTSA on 05/07/2025

DISPOSE OF FOLLOWING PARTS FROM PARTS KIT

VII.

REMOVE FUEL SUCTION TUBE ASSEMBLY
Use TIS to confirm that this vehicle is eligible for the campaign before
proceeding. Warranty will not pay claims on ineligible vehicles.
1. CHECK FOR DTC’S
a. Using GTS+, perform a Health Check to check for Diagnostic
Trouble Codes.
Note: This Special Service Campaign covers only the replacement of the
fuel pump and associated parts. It does not cover the diagnosis or
replacement of any other parts on the vehicle.

REMOVAL TIP: FUEL LEVEL
If the fuel level inside the fuel tank is above 1/3 of a tank, fuel may overflow from the fuel tank
during the removal of the fuel suction tube assembly. Confirm the fuel level in the vehicle is below
the specified level before proceeding. If necessary, drain fuel from the tank. Note that the guest
owner letter for this campaign will recommend for the guest to arrive with the specified fuel level
or less to reduce the amount of time needed by the technician to drain fuel. However, this is not a
requirement for the guest. Refer to the Dealer Letter for a sample of the owner letter.
Note: If fuel needs to be removed from the tank, be sure to recover it into an approved fuel
recovery system. Suitable systems are available from the Lexus Approved Dealer Equipment
website.

8
Submitted to NHTSA on 05/07/2025

REMOVAL TIP: CAM LOCK STYLE RETAINER
A set of Cam Lock Claws and Support Columns was previously supplied to each dealership for
use with Safety Recall 20LA01 in May 2020. The configuration of the retainer engagement sections
of those claws is an improved design over the SST version that is referenced in the TIS repair
manual. These NEW claws that were shipped for 20LA01 are an improved design that enables a
firm attachment to the retainer. In addition to the claws, two support columns were provided which
will support the retainer more securely during installation and removal. Be sure to assemble and
use the tools using the following procedures.

Campaign Tool Cam Lock Set:

9
Submitted to NHTSA on 05/07/2025

10
Submitted to NHTSA on 05/07/2025

REMOVAL TIP: CAM LOCK STYLE RETAINER (cont.)

Lightly tighten the adjuster

Fully tighten the 4 bolts

11
Submitted to NHTSA on 05/07/2025

REMOVAL TIP: TUBE ASSY REMOVAL

1)
2)

Slightly raise the fuel suction tube assembly during
this operation to make sure that the sender gauge
does not interfere with the inside of tank.
Pull up the fuel suction tube assembly to the
position indicated in the illustration. Pull portion (A)
by hand to swing the lower part of fuel suction tube
assembly downward, and then remove the fuel
suction tube assembly from the tank.
• DO NOT bend the arm of fuel sender

gauge assembly.
• DO NOT damage the wire harness at
edges of service hole when removing
the fuel suction tube assembly.

REMOVAL TIP: FUEL LEVEL SENDER
When removing and reinstalling the Fuel Level Sender from the fuel tank, take extra care with
the arm of the fuel sender. It can be easily bent. Additionally, do not touch the electric circuit
of the sender assembly.

Do not touch the electric
circuit of the fuel sender
gauge.

Do not deform the arm of the
fuel sender gauge.

2. REMOVE FUEL SUCTION TUBE ASSEMBLY FROM VEHICLE
a. Click the link Removal ES 300h 2019 to access the repair manual instructions on TIS for
removing the fuel suction tube assembly from the vehicle.
12
Submitted to NHTSA on 05/07/2025

VIII. DISASSEMBLE FUEL SUCTION TUBE ASSEMBLY
DISASSEMBLY TIP: MAIN VALVE AND REGULATOR
When replacing the fuel pump, it is not necessary to remove the Fuel Main Valve or Fuel
Pressure Regulator. These O-Rings are NOT included in the parts kit.

DISASSEMBLY TIPS: O-RING REMOVAL
During disassembly, the O-Ring may remain in the fuel pump housing. Be sure the inspect the
housing after removing the fuel pump and remove the O-Ring if necessary.

13
Submitted to NHTSA on 05/07/2025

1. DISASSEMBLE FUEL SUCTION TUBE ASSEMBLY
a. Click the link Disassembly ES 300h 2019 to access the repair manual instructions on TIS for
disassembling the fuel suction tube assembly.
2. CLEAN SUB TANK ASSEMBLY
a. Using brake cleaner, clean the sub-tank assembly.

IX.

REASSEMBLE FUEL SUCTION TUBE ASSEMBLY
REASSEMBLY TIPS: O-RINGS

The part kits may come with O-Rings of different sizes. They are very difficult to tell apart visually.
To identify the different size O-Rings, they will be wrapped in individual plastic bags with a piece of
COLORED TAPE sealing it. The COLOR OF THE TAPE will identify the O-Ring size.
REFER TO THE COMPONENT DIAGRAMS IN THIS DOCUMENT TO DETERMINE TO
CORRECT O-RING.

14
Submitted to NHTSA on 05/07/2025

1. REASSEMBLE FUEL SUCTION TUBE ASSEMBLY WITH NEW FUEL PUMP
a. Follow the TIS Repair Manual instructions to reassemble the Fuel Suction Tube Assembly
with a NEW Fuel Pump.
Refer to the Component diagrams at the beginning of these Technical
Instructions to confirm the location of each replacement part.
Example Procedure:
• Remove the original O-Ring, Spacer and
Fuel Filter from the original Fuel Pump.
• Discard the original O-Ring and Fuel
Pump, saving the Spacer and Fuel Filter.
• Install the original Spacer onto the NEW
Fuel Pump.
• Install the NEW O-Ring onto the NEW Fuel
Pump. Refer to the Component Diagram to
determine to proper O-Ring, as identified
by the colored tape on the bag.
• Apply a small amount of engine oil to the
NEW O-Ring to assure correct installation
into the Tube Assembly.
• Install the original Fuel Filter onto the NEW
HINT:
Fuel Pump.
The reused filter may be discolored.
• Refer to the Components diagrams to
review the other NEW parts to install.
• Apply engine oil to the NEW O-ring before assembly to assure correct installation
into the Fuel Suction Tube.
Note: Fuel Pump O-Ring installation is critical to this repair. A visual inspection of the
final assembly will confirm the correct installation.

15
Submitted to NHTSA on 05/07/2025

2. REASSEMBLE FUEL SUCTION TUBE ASSEMBLY
a. Click the link Reassembly ES300h 2019 to access the repair manual instructions on TIS for
reassembling the fuel suction tube assembly.

X.

INSTALL FUEL SUCTION TUBE ASSEMBLY

1. INSTALL THE FUEL SUCTION TUBE ASSEMBLY INTO VEHICLE
a. Click the link Installation ES 300h 2019 to access the repair manual instructions on TIS for
installing the fuel suction tube assembly into the vehicle.
Refer to the Component diagrams at the beginning of these Technical
Instructions to confirm the location of each replacement part.
2. REMOVED FUEL
a. If fuel was removed from the tank prior to disassembly, reinstall the originally recovered fuel
into the tank.
3. CHECK FOR DTC’S
a. Using GTS+, perform a Health Check to check for Diagnostic Trouble
Codes.
Note: This Special Service Campaign covers only the replacement of the
fuel pump and associated parts. It does not cover the diagnosis or
replacement of any other parts on the vehicle.

◄ VERIFY REPAIR QUALITY ►
•
•
•
•
•

Confirm that all parts listed in the Components Diagrams have been properly
installed on the vehicle
Confirm no fuel leaks from vehicle
Confirm any fuel drained from the vehicle has been reinstalled
Confirm no DTC’s are present
Test drive to confirm normal operation while under load

16
Submitted to NHTSA on 05/07/2025

XI.

APPENDIX

A. PARTS DISPOSAL
In accordance with Federal law, please make sure all parts (original parts)
removed from the vehicle are disposed of in a manner in which they will not be reused,
unless requested for parts recovery return.

B. CAMPAIGN DESIGNATION DECORDER

Examples:
19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall
Launched in 2019
20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign
Launched in 2020
21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program
Launched in 2021

17
Submitted to NHTSA on 05/07/2025