Lexus GS300/400 (2000 year). Service manual - part 204

P09286

New O–ring

CORRECT

WRONG

Grommet

Injector

Delivery Pipe

B01575

O–Ring

Delivery Pipe

Grommet

Spacer

Insulator

O–Ring

B02046

Push

B02045

Push

Pull

SF–4

–

SFI (2JZ–GE)

SFI SYSTEM

1470

(c)

Observe these precautions when removing and installing
the injectors.
(1)

Never reuse the O–ring.

(2)

When placing a new O–ring on the injector, take
care not to damage it in any way.

(3)

Coat a new O–ring with spindle oil or gasoline be-
fore installing–never use engine, gear or brake oil.

(d)

Install the injector to the delivery pipe and intake manifold
as shown in the illustration.
Before installing the injector, must apply spindle oil or gas-
oline on the place where a delivery pipe or an intake man-
ifold touches an O–ring of the injector.

(e)

Observe these precautions when disconnecting the fuel
tube connector (quick type):
(1)

Check if there is any dirt like mud on the pipe and
around the connector before disconnecting them
and clean the dirt away.

(2)

Be sure to disconnect with hands.

(3)

When the connector and the pipe are stuck, push
and pull the connector to free to disconnect and pull
it out. Do not use any tool at this time.

(4)

Inspect if there is any dirt or the likes on the seal sur-
face of the disconnected pipe and clean it away.

(5)

Prevent the disconnected pipe and connector from
damaging and mixing foreign objects by covering
them with a vinyl bag.

(f)

Observe these precautions when connecting the fuel
tube connector (quick type):
(1)

Check if there is any damage or foreign objects on
the connected part of the pipe.

(2)

Match the axis of the connector with axis of the pipe,
and push in the connector until the connector
makes a ”click” sound. In case the connections is
tight, apply little amount of new engine oil on the tip
of the pipe.

B02077

Pull

B01982

LEXUS
Hand–Held
Tester

–

SFI (2JZ–GE)

SFI SYSTEM

SF–5

1471

(3)

After having finished the connection, check if the
pipe and the connector are securely connected by
pulling them.

(4)

Check if there is any fuel leakage.

(g)

Observe these precautions when handling nylon tube.
(1)

Pay attention not to turn the connected part of the
nylon tube and quick connector with force when
connecting them.

(2)

Pay attention not to kink the nylon tube.

(3)

Do not remove the EPDM protector on the outside
of the nylon tube.

(4)

Must not close the piping with the nylon tube by
bending it.

(h)

Check that there are no fuel leaks after doing mainte-
nance anywhere on the fuel system.
(1)

Connect a LEXUS hand–held tester to the DLC3.

(2)

Turn the ignition switch ON and push the LEXUS
hand–held tester main switch ON.

NOTICE:
Do not start the engine.

(3)

Select the ACTIVE TEST mode on the LEXUS
hand–held tester.

(4)

Please refer to the LEXUS hand–held tester opera-
tor’s manual for further details.

(5)

If you have no LEXUS hand–held tester, connect
the positive (+) and negative (–) leads from the bat-
tery to the fuel pump connector.
(See page 

SF–6

)

(6)

Check that there are no leaks from any part of the
fuel system.

(7)

Turn the ignition switch OFF.

(8)

Disconnect the LEXUS hand–held tester from the
DLC3.

(9)

Start the engine.

NOTICE:
Keep cranking the engine until the air is removed from the
fuel line.

(10) After the engine starts, check again that there are

no fuel leaks.

SF0N4–01

B01876

B01877

Pull

Remove

Plug

B01878

B01874

Fuel
Sub Suction 
Hose

–

SFI (2JZ–GE)

FUEL PUMP

SF–11

1477

REMOVAL

CAUTION:
Do not smoke or work near an open frame when working
the fuel pump.
1.

REMOVE REAR SEAT CUSHION

2.

REMOVE FLOOR SERVICE HOLE COVER

Remove the 3 cap nuts and service hole cover.
3.

DISCONNECT FUEL PUMP & SENDER GAUGE CON-
NECTOR

4.

DISCONNECT FUEL TANK MAIN TUBE (FUEL TUBE
CONNECTOR) FROM FUEL SECTION PLATE

CAUTION:

Perform disconnecting operation of the fuel tube con-
nector (quick type) after observing precaution. (See
page 

SF–1

)

As there is retained pressure in the fuel line, prevent
it from splashing inside the vehicle compartment.

(a)

Remove the tube joint clip.

(b)

Pull out the fuel main tube.

(c)

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

5.

REMOVE FUEL PUMP AND SENDER GAUGE AS-
SEMBLY FROM FUEL TANK

(a)

Remove the 8 bolts and fuel tank vent tube set plate.

(b)

Lift up the fuel pump and sender gauge assembly, and
disconnect the fuel sub suction hose from the fuel return
jet tube and remove the fuel pump, sender gauge assem-
bly and gasket.

6.

REMOVE NO.2 FUEL SUCTION SUPPORT
(See page 

SF–17

)

7.

REMOVE FUEL PRESSURE REGULATOR AND FUEL
RETURN JET TUBE ASSEMBLY (See page 

SF–17

)

B01887

B01889

Pry

Pry

B01890

Pull

B01891

Pull

SF–12

–

SFI (2JZ–GE)

FUEL PUMP

1478

8.

REMOVE FUEL SUCTION FILTER

(a)

Remove the clip.

(b)

Pull out the suction filter.

9.

REMOVE NO.1 FUEL SUCTION SUPPORT

(a)

Using 2 screwdrivers, disconnect the 4 snap claws from
the claw holes and remove the fuel suction support.

NOTICE:
Be careful not to damage the suction support and suction
plate.
(b)

Remove the No.2 fuel filter cushion.

10.

REMOVE FUEL FILTER AND FUEL PUMP ASSEMBLY

(a)

Disconnect the fuel pump connector from the fuel pump.

(b)

Pull out the fuel filter and fuel pump assembly.

(c)

Remove the No.1 fuel filter cushion.

(d)

Remove the O–ring from the fuel poet of the fuel suction
plate.

11.

REMOVE FUEL PUMP FROM FUEL FILTER

Pull out the fuel pump.