LEXUS GS400 2000 Service Repair Manual

FI2553
SST
SF±2
± SFI (2JZ±GE)SFI SYSTEM
1468 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
7. ELECTRONIC CONTROL SYSTEM
(a) Before removing SFI wiring connectors, terminals, etc.,
first disconnect the power by either turning the ignition
switch OFF or disconnecting the negative (±) terminal
cable from the battery.
HINT:
Always check the diagnostic trouble code before disconnecting
the negative (±) terminal cable from the battery.
(b) When installing the battery, be especially careful not to in-
correctly connect the positive (+) and negative (±) cable
terminals.
(c) Do not permit parts to receive a severe impact during re-
moval or installation. Handle all SFI parts carefully, espe-
cially the ECM.
(d) Do not be careless during troubleshooting as there are
numerous transistor circuits and even slight terminal con-
tact can further troubles.
(e) Do not open the ECM cover.
(f) When inspecting during rainy weather, take care to pre-
vent entry of water. Also, when washing the engine
compartment, prevent water from getting on the SFI parts
and wiring connectors.
(g) Parts should be replaced as an assembly.
(h) Care is required when pulling out and inserting wiring con-
nectors.
(1) Release the lock and pull out the connector, pulling
on the connectors.
(2) Fully insert the connector and check that it is locked.
(i) When inspecting a connector with a volt/ohmmeter.
(1) Carefully take out the water±proofing rubber if it is
a water±proof type connector.
(2) Insert the test probe into the connector from wiring
side when checking the continuity, amperage or
voltage.
(3) Do not apply unnecessary force to the terminal.
(4) After checking, install the water±proofing rubber on
the connector securely.
(5) Use SST for inspection or test of the injector or its
wiring connector.
SST 09842±30070

B01875
Fuel
Pump
Connector
B01998
New
Gasket
New
Gasket
FI1654
SST
Fulcrum Length
30 cm
± SFI (2JZ±GE)SFI SYSTEM
SF±3
1469 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
8. FUEL SYSTEM
(a) When disconnecting the high pressure fuel line, a large
amount of gasoline will spill out, so observe these proce-
dures:
(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on
its own, turn the ignition switch OFF.
(3) Put a container under the connection.
(4) Slowly loosen the connection.
(5) Disconnect the connection.
(6) Plug the connection with a rubber plug.
(7) Reconnect the fuel pump connector.
(b) When connecting the flare nut or union bolt on the high
pressure pipe union, observe these procedures:
(1) Union Bolt Type:
Always use a new gasket.
(2) Union Bolt Type:
Tighten the union bolt by hand.
(3) Union Bolt Type:
Tighten the union bolt to the specified torque.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(4) Flare Nut Type:
Apply a light coat of engine oil to the flare and tight-
en the flare nut by hand.
(5) Flare Nut Type:
Using SST, tighten the flare nut to the specified
torque.
SST 09631±22020
NOTICE:
Do not rotate the fuel pipe, when tightening the flare nut.
Torque:
30 N´m (310 kgf´cm, 22 ft´lbf) for using SST
38 N´m (387 kgf´cm, 28 ft´lbf)
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

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 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(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 ºclickº 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 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(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 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
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 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
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.

SF0N5±02
B02037
Push
B01892
Fuel Port Hole
No.1 Fuel Filter
Cushion
Fuel Port
New O±Ring
B01893
B02038
Snap Claw
Push
B01887
New Clip
± SFI (2JZ±GE)FUEL PUMP
SF±13
1479 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
INSTALLATION
1. INSTALL FUEL PUMP TO FUEL FILTER
Push in the fuel pump.
2. INSTALL FUEL FILTER AND FUEL PUMP ASSEMBLY
(a) Install the No.1 fuel filter cushion to the fuel suction plate.
(b) Apply a light coat of gasoline to a new O±ring and install
it to the fuel port of the fuel suction plate.
(c) Align the fuel port of the fuel suction plate with the fuel port
hole of the fuel filter.
(d) Push in the fuel filter.
(e) Connect the fuel pump connector.
3. INSTALL NO.1 FUEL SUCTION SUPPORT
(a) Install the No.2 fuel filter cushion to the fuel filter.
(b) Push the fuel suction support, and attach the 4 snap
claws to the claw holes.
4. INSTALL FUEL SUCTION FILTER
Install the suction filter with a new clip.
5. INSTALL FUEL PRESSURE REGULATOR AND FUEL
RETURN JET TUBE ASSEMBLY (See page SF±18)
6. INSTALL NO.2 FUEL SUCTION SUPPORT
(See page SF±18)

B01874
Fuel
Sub Suction
Hose
B01878
B02043
Attach
Install
B01876
SF±14
± SFI (2JZ±GE)FUEL PUMP
1480 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
7. INSTALL FUEL PUMP AND SENDER GAUGE AS-
SEMBLY TO FUEL TANK
(a) Install a new gasket to the fuel suction plate.
(b) Connect the fuel sub suction hose to the fuel return jet
tube.
(c) Attach the fuel pump and sender gauge assembly to the
fuel tank.
(d) Install the fuel tank vent tube set plate with the 8 bolts.
Torque: 3.5 N´m (36 kgf´cm, 31 in.´lbf)
8. CONNECT FUEL TANK MAIN TUBE (FUEL TUBE CON-
NECTOR) TO FUEL SUCTION PLATE
(a) Attach the fuel tube connector to the port of the fuel suc-
tion plate.
(b) Install the tube joint clip.
9. CONNECT FUEL PUMP & SENDER GAUGE CONNEC-
TOR
10. CHECK FOR FUEL LEAKS (See page SF±1)
11. INSTALL FLOOR SERVICE HOLE COVER
Install the service hole cover with the 3 cap nuts.
12. INSTALL REAR SEAT CUSHION

SF0N6±01
B01873
Rear Seat Cushion
Floor Service Hole Cover
Fuel Pump & Sender Gauge
Connector
Fuel Tank Vent Tube
Set PlateFuel Tank Main Tube
Tube Joint Clip
Fuel Pump and Sender Gauge
Assembly
Fuel Sub Suction Hose

Non±reusable part

Gasket
x 8
N´m (kgf´cm, ft´lbf) : Specified torque
3.5 (36, 31 in.´lbf)
± SFI (2JZ±GE)FUEL PRESSURE REGULATOR
SF±15
1481 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
FUEL PRESSURE REGULATOR
COMPONENTS

B01883
Fuel Return
Jet Tube
Rubber Cushion
No.2 Fuel Suction
SupportFuel Pressure
Regulator
O±RingFuel Pressure Regulator
and Fuel Return Jet
Tube Assembly

Non±reusable part
SF±16
± SFI (2JZ±GE)FUEL PRESSURE REGULATOR
1482 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)